JPH08226466A - Manufacture of caliper body in disk brake for vehicle - Google Patents

Abstract

PURPOSE: To ensure a higher strength property than that of castings as a caliper body of integrated type without dividing bridge parts while mounting a ceiling opening part allowing a friction pad to be put in and out in the bridge part. CONSTITUTION: A metal material like aluminum alloy is extruded in the arrow mark A direction namely in the axial direction of a ceiling opening part 2d by an extruding machine to mold a mold material 7. The mold material 7 is formed therein with the ceiling opening part 2d, vehicle mounting holes 2e, 2e and lightening holes 2f, 2f extending therethrough longitudinally thereof. The mold material 7 is formed on the outside longitudinally with the external form of a caliper body 2 and a plurality of cooling fins 2g attached to the external form. The ceiling opening part 2d, vehicle mounting holes 2e, 2e and lightening holes 2f, 2f are formed therearound with forget flow lines G having continuous fiber texture of the material molded by the extruding machine. The mold material 7 is cut off longitudinally and transversely at a position corresponding to the radial length of the disk of the caliper body 2 to form a caliper body blank 8.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for integrally manufacturing an entire caliper body of a disc brake used in various traveling vehicles such as automobiles.

[0002]

2. Description of the Related Art A caliper body for a disc brake used in an automobile or the like faces a pin slide type in which the caliper body at the time of braking is slid in the disc axial direction by the guide of a guide pin, and the caliper body faces without sliding. It is roughly divided into an opposed type that pushes out both pistons inserted in a pair of action parts and performs braking action, and from the configuration form of the caliper body, a configuration in which a plurality of divided pieces are combined is a divided type, There is a method of dividing the structure formed by one into an integrated type, and in any case, a ceiling opening capable of inserting and removing the friction pad is formed in the bridge portion without removing the caliper body from the vehicle body. There is one that makes it possible to easily replace the friction pad. (For an example of a caliper body with a ceiling opening, see Jpn. .

Further, these caliper bodies are generally formed by casting or press molding. For example, Japanese Patent Application Laid-Open Nos. 5-161911 and 161912 propose a manufacturing method by extrusion molding. Among them, the former technique is characterized in that a knuckle having a holding portion of an axle and a connecting portion with a vehicle body and a divided piece on a working portion having a cylinder hole for accommodating a piston are integrally formed by extrusion molding. Also, in the latter technique, a step of extruding a divided piece on the side of the action portion having a cylinder hole for accommodating a piston in the axial direction of the cylinder hole, and a divided piece on the side of the reaction portion having a reaction force pawl are disc-shaped. It is characterized in that it includes a step of extruding in the turning-in and feeding-out directions and a step of integrally joining the divided pieces on the action portion side and the reaction portion side, and in both cases, the caliper body is cast-molded. It is said that higher rigidity and toughness can be obtained.

[0004]

However, the above-mentioned two methods can be applied only when the caliper body is a split type and a pin slide type, and other caliper bodies of opposite type and body integrated type are not applicable. It cannot be manufactured. Also, when the disc brake is activated, the action part and reaction part of the caliper body are pushed back in the direction opposite to the disc rotor by the braking reaction force from the friction pad, and the caliper body is shaped like a square C with the bridge part as a fulcrum. It is well known that the bridge part where the stress of the C-shaped deformation concentrates is divided in either method, so the bridge part is thicker than the integrated type, It must be reinforced by inserting reinforcing bolts and retainers. Furthermore, if a ceiling opening having a large area is set in the above-mentioned bridge portion, the abutting area between the action portion side and the reaction portion side is reduced, and the rigidity of the bridge portion is further reduced. Measures are needed. On the other hand, the body-integrated pin slide type and the body-integrated type or split type opposing type are mainly formed by casting, but in the case of a cast molded product having the same thickness as the extrusion molded product, the extrusion molding is performed as described above. There is a problem that it is difficult to obtain the high rigidity and toughness of the product.

Therefore, the present invention secures higher strength characteristics than the cast product while providing the bridge opening with a ceiling opening through which a friction pad can be inserted and removed, and can be applied to a pin slide type or an opposed type. Moreover, it is an object of the present invention to provide a method for manufacturing an integrated caliper body that does not divide the bridge portion.

[0006]

In order to achieve such an object, the present invention manufactures a caliper body having a ceiling opening for inserting / removing a friction pad in a bridge portion arranged over the outer circumference of a disk rotor. In the method, a metal material is extruded in the axial direction of the ceiling opening, the ceiling opening is formed inside the extruded mold material, and the outer shape of the caliper body is also formed outside the mold material in the longitudinal direction of the mold material. The method is characterized by including a step of forming the mold material and a step of cutting the mold material at right angles to the longitudinal direction.

Further, when the bolt holes for mounting the vehicle body, the heat radiation fins, and the lightening holes are set in the caliper body in the same direction as the ceiling opening, they can be integrally formed by the above-described method. .

[0008]

Since the caliper body is integrally formed from the primary processed product obtained by cutting the extruded mold material to a predetermined length, the assembly process like the conventional split mold is unnecessary.
Further, secondary processing such as cutting can be simplified. In the entire extruded mold material, the strength such as rigidity and toughness higher than that in casting and the accuracy of dimensions and surface roughness etc. are secured, and in the bridge part where the stress due to the braking reaction force concentrates, the fiber structure of the metal material A grain flow line that continuously surrounds the ceiling opening is formed. This grain flow has high strength in the state where the fiber structure is continuous, and does not show so much strength if the grain flow is cut by cutting, but the ceiling opening is smooth with high dimensional accuracy by extrusion molding. Since it can be formed in the above-described manner, and the cutting finish of the inner surface can be eliminated, the bridge portion around the ceiling opening can retain high strength due to grain flows. Furthermore, the inner surface of the ceiling opening may be used as the torque receiving surface that supports the side surface of the friction pad as it is.

[0009]

An embodiment of the present invention will be described below with reference to the drawings. 1 is a perspective view of the mold material, FIG. 2 is a plan view of the mold material, FIG. 3 is a sectional plan view of the disc brake, and FIG. 4 is a sectional view taken along line IV-IV of FIG.

The caliper body 2 used for the disc brake 1 has a bridge portion 2c straddling the outer periphery of the disc rotor 3.
A pair of operating portions 2a and 2b connected to both sides of the disk rotor 3 are opposed to each other on both sides of the disk rotor 3, and pistons are respectively provided in the operating portions 2a and 2b, which are arranged in parallel and open toward the disk rotor side. 5, a rectangular ceiling opening 2d is provided in the center of the bridge portion 2c, and a pair of a pair of operating portions 2a and 2b sandwiching the disk rotor 3 is provided between them. The friction pads 6 and 6 are inserted and removed through the ceiling opening 2d.

The caliper body 2 has two processes, namely, a primary process for cutting the long mold material 7 shown in FIG. 1 into a required length to obtain a caliper body material 8, and a process for cutting the caliper body material 8 after the primary process. It is formed by subsequent processing. Template 7
Is a metal material of the caliper body 2 such as an aluminum alloy extruded by an extruding machine (not shown) in the direction of arrow A which is the axial direction of the ceiling opening 2d.
In addition to the above-described ceiling opening 2d, the inside of the vehicle body mounting hole 2 for radially mounting the caliper body 2 on the vehicle
e, 2e and the lightening holes 2f, 2f are respectively formed by the mold member 7
The outer shape of the caliper body 2 and a plurality of cooling fins 2g attached to the outer shape are formed on the outside of the mold member 7 along the longitudinal direction of the mold member 7. It is integrally formed.

In the die member 7 extruded as described above, a grain flow in which a fibrous structure of a metal material is continuous around the ceiling opening 2d, the vehicle body mounting holes 2e, 2e and the lightening holes 2f, 2f. A line G is formed, and the mold member 7 is positioned at a position C corresponding to the length of the caliper body 2 in the radial direction of the disk.
Then, by cutting in the direction orthogonal to the longitudinal direction, the caliper body material 8 having the same shape is sequentially taken out as a primary processed product.

The caliper body material 8 has secondary cylinder holes 4, female screw holes 9, seal grooves 10, rotor grooves 11, etc., which are not formed by the above-mentioned primary processing and are oriented in a direction different from the axis of the ceiling opening 2d. Cutting is performed as processing, and by this secondary processing, the caliper body 2 shown in FIGS. 3 and 4 is formed. After the secondary processing, the corner seal 12 is mounted in the seal groove 10, the piston 5 is mounted in the cylinder hole 4, and the plug cap 13 is screwed into the female screw hole 9 in the acting portion 2a on the vehicle body mounting side. By wearing
A cylinder hole 4 similar to the other acting portion 2b is defined in front of the plug cap 13.

The friction pad 6 has a ceiling opening 2
It is inserted between the disc rotor 3 and the piston 5 through d, and is suspended by the hanger pins 14 and 14 installed on both working portions 2a and 2b.
The two surfaces that sandwich the friction pads 6 and 6 on the inner side in the radial direction of the disk are torque receiving surfaces 15 and 15.

As described above, in the present embodiment, the opposed caliper body 2 is integrally formed from the caliper body material 8 obtained by cutting the extrusion-molded mold material 7 to a required length, so that the rigidity and toughness are higher than those of conventional casting. And the strength of the bridge portion 2c can be improved while eliminating the assembling process, as compared with the conventional opposing mold formed by extrusion molding which has to be divided into a plurality of pieces. .

Further, the extrusion direction of the mold member 7 is set to the ceiling opening 2
By forming the ceiling opening 2d, the vehicle body mounting holes 2e, 2e, the lightening holes 2f, 2f, the outer shape of the caliper body 2 and the cooling fins 2g in the axial direction of d along the longitudinal direction of the mold member 7. Since high dimensional accuracy and fine surface roughness can be obtained in the entire caliper body 2 and these openings and holes, it is possible to largely omit the secondary processing such as cutting and finishing after the primary processing. Therefore, the torque receiving surfaces 15 and 15 can be used as they are inside the ceiling opening 2d in the radial direction of the disk.

Further, the ceiling opening 2d and the vehicle body mounting hole 2 are provided.
Since e, 2e and the lightening holes 2f, 2f are surrounded by a grain flow line G in which the fiber structure of the metal material is continuous, the strength of these openings and holes can be maintained well. In particular, in the bridge portion 2c where stress is concentrated due to the C-shaped deformation due to the braking reaction force, coupled with the fact that the caliper body 2 is an integral type, the grain flows G reinforce around the ceiling opening 2d, You will be able to withstand the stress of deformation. Therefore, in the caliper body 2 of the present embodiment, it is not necessary to thickly build up the bridge portion 2c or insert a reinforcing bolt or a retainer for reinforcement although the bridge portion 2c has the ceiling opening 2d. The entire structure can be made lightweight and compact.

It should be noted that, as shown in the above embodiment, another shape set in the same direction as the axis of the ceiling opening can be formed by extrusion molding, but in the method of the present invention,
It is sufficient if at least the ceiling opening and the outer shape of the caliper body are extruded. A pin slide type caliper body can also be formed by performing machining such as cutting after primary processing using the present invention.

[0019]

As described above, according to the method of the present invention, the extruded mold material is cut into a required length, and the opposed type or pin slide type caliper body is integrally formed by using the primary processed product. The strength such as rigidity and toughness can be secured compared to the conventional one-piece type by casting, and the assembly process is unnecessary as compared with the conventional extrusion type that had to be divided into multiple pieces. Meanwhile, the strength of the bridge portion can be improved.

Further, by setting the extrusion direction of the mold material in the axial direction of the ceiling opening, and by forming the outer shape of the ceiling opening and the caliper body along the longitudinal direction of the mold material, a high dimensional accuracy is achieved over the entire caliper body. Since a fine surface roughness can be obtained, secondary processing such as cutting and finishing after primary processing can be greatly omitted, and the torque receiving surface can be used as it is inside the ceiling opening in the radial direction of the disk. You can also do it.

Further, since the grain flow line in which the fibrous structure of the metal material is continuous surrounds the ceiling opening formed by extrusion,
At the bridge where stress concentrates due to the V-shaped deformation due to the braking reaction force, coupled with the fact that the caliper body is integrally formed, the grain flows reinforce around the ceiling opening and the stress of the H-shaped deformation occurs. You will be able to bear it well. Therefore, although the bridge portion has the ceiling opening portion, it is not necessary to thickly build up the bridge portion or insert a reinforcing bolt or a retainer for reinforcement, so that the caliper body can be formed lightweight and compact. it can.

[Brief description of drawings]

FIG. 1 is a perspective view of a mold material showing an embodiment of the present invention.

FIG. 2 is a plan view of a mold material showing an embodiment of the present invention.

FIG. 3 is a sectional plan view of a disc brake showing an embodiment of the present invention.

4 is a sectional view taken along the line IV-IV in FIG.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Disc brake 2 ... Opposing caliper bodies 2a, 2b ... Action part 2c ... Bridge part 2d ... Ceiling opening 2e ... Vehicle body mounting hole 2f ... Lightening hole 2g ... Cooling fin 3 ... Disk rotor 4 ... Cylinder hole 5 ... Piston 6 ... Friction pad 7 ... Extruded mold material 8 ... Caliper body material as a primary processed product obtained by cutting mold material 7 to a required length 9 ... Female screw hole 10 ... Seal groove 11 ... Rotor groove 12 ... Square seal 13 ... Plug cap 14 ... Hanger pin 15 ... Torque receiving surface formed by using the ceiling opening 2d A ... Extrusion direction of the mold material C ... Cutting position for taking out the caliper body material 8 from the mold material G ... Grade line

Claims (1)

[Claims] 1. A method of manufacturing a caliper body having a ceiling opening for inserting and removing a friction pad in a bridge portion arranged over the outer circumference of a disk rotor, wherein a metal material is applied in an axial direction of the ceiling opening. Extrusion molding, forming a ceiling opening inside the extruded mold material, and also forming the outer shape of the caliper body on the outside of the mold material along the longitudinal direction of the mold material, respectively, and the mold material orthogonal to the longitudinal direction. A method of manufacturing a caliper body for a vehicle disc brake, comprising: