JPH05293626A - Manufacture of brake calliper - Google Patents

Abstract

PURPOSE:To provide the method for manufacturing brake calliper which can miniaturize the size and lighten the weight of calliper, and improve the freedom of the design system inside a wheel, which is excellent in responsiveness, and whose working cost is reduced. CONSTITUTION:A metallic tube 2 forming a hydraulic pressure supplying hole is arranged in a mold, and the casting is executed so as to cast inserting this tube. As the metallic tube 2, the material of an Al material, a Ni plated Al material, a SUS 304 material, and a Ni plated SUS 304 material, etc., can be suitably utilized. A high pressure solidification casting method for solidifying under a high pressure is utilized for casting. Accordingly, since the hydraulic pressure supplying hole can be formed to a gently curved line or a straight line shape, in comparison with the hydraulic supplying hole of zigzag shape, the calliper can be miniaturized in size and lightened in weight, the flow resistance of the oil inside the hydraulic pressure supplying hole is small, the transmitting speed of the hydraulic pressure is increased, and the responsiveness of the braking operation is improved.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an improved method of manufacturing brake calipers.

[0002]

2. Description of the Related Art As shown in FIG. 2, a conventional brake caliper has a block 1 of a brake caliper produced by casting, and a hydraulic pressure supply hole 1 communicating with its cylinder portions 1A and 1B.
A, 1b, 1c, 1d, 1e and 1f were formed by machining. In that case, in order to secure a thickness of 1g after processing, the thickness of 1h
Therefore, there is a problem that the weight is increased and the degree of freedom of design within the foil is limited. Also, the hydraulic pressure supply holes 1a, 1b, 1c, 1d, 1e,
There is also a problem that due to the processed shape of 1f, the oil propagation speed decreases and the responsiveness decreases, and that the processing cost increases.

[0003]

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and an object of the present invention is to make a caliper small and lightweight and to have a degree of freedom in design in a wheel. It is an object of the present invention to provide a method for manufacturing a brake caliper, which is capable of improving the operation efficiency, has excellent responsiveness, and requires less processing cost.

[0004]

In order to achieve the above-mentioned object, a method for manufacturing a brake caliper according to the present invention is arranged such that a metal pipe forming a hydraulic pressure supply hole is arranged in a mold and the pipe is surrounded. It is characterized in that casting is performed with an aluminum alloy. As the metal pipe, Al material,
Materials made of Ni-plated Al material, SUS304 material, Ni-plated SUS304 material and the like can be preferably used. Further, the above casting, high pressure solidification casting method to perform solidification under high pressure according to the following conditions, i.e., molten aluminum alloy, from the sprue having a thickness of the product part maximum wall thickness or more, sprue inflow velocity 0.15 ~ 0.4m / At s, it is injected by the low-speed laminar flow filling method, and casting is performed by the high-pressure solidification casting method in which the casting temperature is 700-800 ° C and the solidification is performed under the pressure of 500-2000 kgf / cm ² by the two-stage pressure plunger. Is recommended.

[0005]

Since the present invention is constructed as described above, according to the present invention, it is not necessary to take an excessive wall thickness, the caliper can be made small and lightweight, and the degree of freedom of design in the foil can be increased. It is possible to provide a method for manufacturing a brake caliper that can be improved, has excellent responsiveness, and requires less processing cost.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT A brake caliper manufactured by the manufacturing method according to the present invention will be described in detail below with reference to FIG. In FIG. 1, 1 is a block of a brake caliper, 2 is a metal pipe that forms a hole for hydraulic pressure cast therein, and 2a and 2b are open to the metal pipe 2 so as to communicate with the cylinder parts 1A and 1B. It is a bored hole. The dashed-dotted line in FIG. 1 indicates the size of the conventional product shown in FIG.

In manufacturing the brake caliper, a metal pipe 2 is set in a mold in advance, and then an aluminum alloy molten metal is injected into the mold to cast the pipe in a round shape. Is. As the material of the metal pipe, Al is selected from the viewpoint of the bond strength with the aluminum alloy forming the block 1 and the equivalence of the coefficient of thermal expansion.
Material, Al material plated with Ni, SUS304 material, Ni
A plated SUS304 material or the like can be preferably used.

With the above-mentioned structure, even if the same thickness 1g as the conventional product shown in FIG. 2 is secured, the thickness 1h 'is remarkably thinner than the conventional product 1h. The size and weight of can be reduced. Therefore, the degree of freedom in designing the caliper in the wheel is increased, and a design that was impossible in the past at the design stage can be adopted. Further, since the hydraulic pressure supply hole can be formed in a gentle curve or linear shape without having the zigzag shape shown in FIG. 2, the oil flow resistance is small, the hydraulic pressure propagation speed is increased, and the responsiveness of brake operation is increased. Is improved. Furthermore, the machining cost is low because the holes 2a and 2b communicating with the cylinder portions 1A and 1B are only opened in the pipe 2.

As a casting method for producing the caliper block 1 by casting the metal pipe 2 with an aluminum alloy, it is recommended to use what is called a high pressure solidification casting method. In that case, the molten metal flow rate of the aluminum alloy from the gate with a thickness greater than the maximum wall thickness of the product
Pouring at a low velocity laminar flow filling method at 0.15 to 0.4 m / s and casting temperature at 700 to 800 ℃ with a two-stage pressure plunger from 500 to
The coagulation is performed under a pressure of 2000 kgf / cm ² . According to such a high pressure solidification casting method, the molten metal is strongly adhered to the mold by pressurization during solidification, so that the solidification rate can be increased, a dense and uniform structure can be obtained, and the tensile strength and fatigue strength can be improved. However, the coupling force with the metal pipe 2 is also improved.

[0010]

Since the present invention is constructed as described above, according to the present invention, the caliper can be made smaller and lighter, the degree of freedom of design in the wheel can be improved, and the braking operation can be improved. It is possible to provide a method for manufacturing a brake caliper that has excellent responsiveness and that requires less processing cost. It should be noted that the present invention is not limited to the above embodiments, and includes all modified embodiments that can be easily conceived by those skilled in the art from the above description within the scope of the object of the present invention.

[Brief description of drawings]

FIG. 1 is an explanatory view showing an example of a brake caliper manufactured by a manufacturing method according to the present invention.

FIG. 2 is an explanatory diagram showing an example of a brake caliper manufactured by a conventional method.

[Explanation of symbols]

 1 Brake caliper block 1A, 1B Cylinder part 2 Metal pipe 2a, 2b hole

Claims (3)

[Claims] 1. A method of manufacturing a brake caliper, characterized in that a metal pipe (2) for forming a hydraulic pressure supply hole is placed in a mold, and the pipe is cast from an aluminum alloy so as to surround the pipe. 2. The method for manufacturing a brake caliper according to claim 1, wherein the metal pipe (2) is an Al material, an Ni material plated with Al, SUS304 material, or a Ni plated SUS304 material. 3. A high-pressure solidification casting method in which the casting is carried out under high pressure under the following conditions, that is, an aluminum alloy melt is produced from a sprue having a thickness not less than the maximum wall thickness of a product part.
High-pressure solidification casting in which pouring is performed at a sprue inlet velocity of 0.15 to 0.4 m / s by a low-speed laminar filling method and solidification is performed at a casting temperature of 700 to 800 ° C under a pressure of 500 to 2000 kgf / cm ² by a two-stage pressure plunger. The method for manufacturing a brake caliper according to claim 1, wherein casting is performed by a method.