JPS6088233A - Method of manufacturing disc brake caliper - Google Patents

Abstract

PURPOSE:To improve the yield of a material by previously forming a necessary circular hole at the center of a strip steel material, and cutting the steel material at the central part of the circular hole to manufacture two caliper materials so that cut portions respectively form half-circular holes. CONSTITUTION:In case of manufacturing a disc brake caliper, a plurality of small holes 4-8 are bored through a steel material 3 twice as long as a U- shaped caliper developed. A punch 9 having a diameter larger than that of the above each small hole 4-8 is pushed in the small holes 4-8 to work the small holes into a designated form. Subsequently, the steep material 3 is cut at a portion 12 passing through the center of the circular hole 6 and perpendicular to the longitudinal direction of the steel material 3 to obtain two caliper materials. The respective caliper materials are bent in such a manner that the longitudinal section is U-shaped to form a forked portion 13, a hole 14 of a cylinder mount portion and a hole 15 for observing a brake pad. Thus, a U-shaped caliper 16 is completed.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a U-shaped caliper that straddles a disc in a disc brake.

In general, a disc brake caliper has a hole for observing the wear state of the brake pad, as well as a mounting hole for the cylinder part or an escape hole for a jig and tool for machining the cylinder part. These holes are extremely large compared to the width of the caliper, and machining of escape holes with jigs and tools is difficult.
It is circular in shape.

Conventionally, as shown in FIG. 1, a method for manufacturing a caliper for a disc brake involves producing a caliper element @2 having the two circular holes and one double circular hole from a ductile steel plate 1 by press punching or other methods. Since it was manufactured using a mechanical processing method, the material yield was poor. Further, in this case, there was a problem in that it was extremely difficult to process the 1/2 circular hole by either press punching or machining.

The present invention has been made in order to solve the above-mentioned problems, and its purpose is to achieve an extremely high material yield and to accurately and easily form the 1/2 circular hole in the bifurcated part of the caliper. The purpose of the present invention is to provide a caliper that can be manufactured in the following manner.

An embodiment of the present invention will be described below based on the drawings.

In Figure 2, a small hole 4 of copper 13i has a length that is approximately twice the length of one U-shaped caliper when expanded.
, 5, 6, 7. 8 are punched out using a press or the like. As shown in FIG. 3, punch 9 having an outer diameter larger than the hole diameter shown in FIG. 2 is strongly pushed in the direction of arrow 10 to first enlarge the hole diameter 4. Next, a punch with a larger outer diameter is similarly pushed in to further increase the hole diameter. This process is repeated until the pore diameter reaches the desired size. The diameters of holes 5, 6, and 7.8 are expanded in the same manner. After processing the shape of each hole to meet the purpose, the steel material 11 shown in FIG. S is done. Next, the steel material 11 is cut at a portion 12, that is, a portion passing through the center of the circular hole 6 and perpendicular to the longitudinal direction of the steel material 11.

Manufactures Nitsuno Caliha Materials 13 and 14. This caliper material 13 or 14 is then bent so that the longitudinal section of the steel material 11 has a U-shape, and the bifurcated portion 13 having the ■/'2 circular hole, the hole 14 of the cylinder mounting portion, and the brake pad are observed. The use hole 15 forms a U-shaped caliper 16.

In this case, annealed sushi may be added to the steel material 1 to facilitate the process of enlarging each hole diameter.

Further, in the above embodiment, a manufacturing method is described in which the required hole diameter is obtained by sequentially enlarging the hole from a small hole, but the method is not limited to this, and the hole diameter shown in FIG. 4 may be provided from the beginning. .

Next, a cup-shaped cylinder 16 having a cylinder hole 16a
is brought into contact with the hole 14 portion of the cylinder mounting portion and joined by friction bonding or the like. The disc brake caliper of the present invention is manufactured in the manner described above.

Since the disc brake caliper is manufactured as described above, the following effects can be achieved by the disc brake caliper manufacturing method of the present invention.

(1) After making a circular hole in the center of a strip-shaped steel material, cut it so that each cut part forms a 172-circle hole, and simultaneously manufacture two pieces of carrier material. This method has a high material yield and is very economical.

(2) Machining is very easy due to (11) features.

(3) Since a steel plate with a large Young's modulus is used for the opening of the cylinder, there is little deformation of the cylinder due to liquid pressure.

[Brief explanation of drawings]

Figure 1 is a process diagram of press punching of caliper material in the conventional disc brake caliper manufacturing method, and Figure 2 (
a, b) are press drawing process diagrams of a caliper material showing an embodiment of the disc brake caliper manufacturing method according to the present invention, in which FIG. 1(a) is a plan view thereof, and FIG. Figures (x-x sectional view of al, Figure 3 is a process diagram of enlarging the small hole shown in Figure 2 using a large diameter punch, Figure 4 is a process diagram of cutting the caliper material after completing the enlarging process of Figure 3, Fig. 5 shows a sectional view of the disc brake caliper. 13... V2 circular hole in the bifurcated part 14... Hole in the cylinder mounting part 15... Observation hole 16... Cup-shaped cylinder agent Patent Attorney Setsuo Mitobe Figure 1 Part 2 (α) 3rd Assignment Figure 4 Figure 2 Figure 2

Claims (1)

[Claims] A circular hole is provided in the center of a rectangular plate material, a first hole and a second hole are provided so as to sandwich the circular hole from both sides in the longitudinal direction of the plate material, and the circular hole portion of the plate material is perpendicular to the longitudinal direction. A caliper material having an η circular hole at the end is manufactured by cutting in the direction of A bridge part having a hole that spans the outer periphery of the disk, and a cylinder mounting part having a second hole are formed, and a cup-shaped cylinder is welded to a position corresponding to the second hole of the cylinder mounting part to form a disc brake. How to manufacture calipers.