JP4339092B2 - Caliper body manufacturing method - Google Patents

Description

  The present invention relates to a method for manufacturing a caliper body used for a disc brake for a vehicle.

Some disc brakes for vehicles have a pair of pads arranged on both sides of the disc, and a piston arranged on the opposite side of each pad to press the pair of pads against the disc. Is called an opposed piston type because the pistons face each other. In this opposed piston type disc brake, an inner side divided body having an inner side cylinder part having a bore for slidably fitting the piston and an inner side torque receiving part for receiving the torque of the pad, and a similar outer side The outer side divided body having the cylinder part and the outer side torque receiving part are separately cast and processed, and the caliper body is formed by connecting the inner side divided body and the outer side divided body with bolts. (For example, refer to Patent Document 1).
JP 2003-269501 A

  However, if the inner side divided body and the outer side divided body are connected with bolts as described above, the rigidity of the connecting portion will be reduced, so the caliper body must be enlarged to ensure rigidity. However, the weight increases. For this reason, the inner side cylinder part, the outer side cylinder part, the inner side torque receiving part, and the outer side torque receiving part of the caliper body are considered to be integrally formed by casting so as to reduce the size and weight. However, the caliper body in which the inner side and the outer side are integrally formed in this way is thin because the thickness in the disk radial direction of the disk path portion that is a boundary portion between the inner side and the outer side passes through the disk. Therefore, the rigidity during use can be secured, but it is deformed when clamped in the axial direction of the cylinder part (disk axial direction) by a processing machine, and the bore processing after casting or mounting perpendicular to the disk axial direction The occurrence of a problem that would affect the accuracy of processing such as holes was expected. Furthermore, since the thickness of the disk path portion in the disk radial direction is thin, it is expected that there will be a problem that the molten metal flow during casting is poor and good casting accuracy cannot be obtained.

  Accordingly, an object of the present invention is to provide a caliper body manufacturing method capable of improving processing accuracy and casting accuracy even when the inner side and the outer side are integrally formed by casting.

  In order to achieve the above object, according to the first aspect of the present invention, a pair of pads are arranged on both sides of a disk, and the pair of pads are attached to the disk by pistons arranged on the opposite side of the disk from the disk. Used for the opposed piston type disc brake to be pressed, and provided with an inner cylinder part and an outer cylinder part each provided with a bore for slidably fitting the piston, and between the inner cylinder part and the outer cylinder part A caliper body having an inner side torque receiving portion and an outer side torque receiving portion each receiving torque of the pair of pads, and a disk path portion connecting the inner side torque receiving portion and the outer side torque receiving portion. The inner side cylinder part, the outer side cylinder part, the inner side torque receiving part and the front The outer side torque receiving part and the disk path part are integrally formed by casting, and the inner side torque receiving part and the outer side torque receiving part are connected to each other in the disk radial direction so as to connect the inner side torque receiving part and the outer side torque receiving part at the time of casting. The intermediate portion is integrally formed, and at least the bore is processed, and then the intermediate portion is removed by processing to form a passage recess of the disk between the inner side torque receiving portion and the outer side torque receiving portion. It is characterized by that.

  The invention according to claim 2 is a counter-piston type disc brake in which a pair of pads are arranged on both sides of the disc and pistons are arranged on the opposite side of the disc to the disc, and the pair of pads are pressed against the disc. The inner side cylinder part and the outer side cylinder part respectively provided with bores for slidably fitting the piston, and the pair of pads respectively between the inner side cylinder part and the outer side cylinder part A caliper body manufacturing method comprising: an inner side torque receiving portion and an outer side torque receiving portion that receive torque of the inner side, and a disk path portion that connects the inner side torque receiving portion and the outer side torque receiving portion, wherein the inner side cylinder Part, the outer side cylinder part, the inner side torque receiving part, the outer side torque receiving part, and the And integrally forming an interstitial part inside the disk radial direction of the disk path part so as to connect the inner side torque receiving part and the outer side torque receiving part at the time of casting. At least after drilling a mounting hole that is drilled in at least the outer cylinder portion and is orthogonal to the disk axial direction, the interposition portion is removed by machining, so that there is no gap between the inner side torque receiving portion and the outer side torque receiving portion. And a passage recess of the disk is formed.

  The invention according to claim 3 is the invention according to claim 1 or 2, wherein a plurality of the bores are provided apart from each other in the disk rotation direction, and the inner side torque is provided between adjacent bores in the disk rotation direction. The receiving portion, the outer side torque receiving portion, the disc path portion, and the interposition portion are integrally formed by the casting.

  According to the first aspect of the present invention, when the inner side cylinder portion, the outer side cylinder portion, the inner side torque receiving portion, the outer side torque receiving portion, and the disc path portion are integrally formed by casting, the inner side torque receiving portion. And the outer side torque receiving part are integrally formed on the inner side in the disk radial direction of the disk path part, and after that, at least the bore is processed, and then the intermediate part is removed by processing, and the inner side torque receiving part And a disc pass recess are formed between the outer torque receiving portion and the outer side torque receiving portion. For this reason, the thickness in the disk radial direction of the boundary portion between the inner side and the outer side at the time of casting becomes thicker due to the interposition part, and as a result, the hot water flow at the time of casting becomes good and the casting accuracy can be improved. In addition, in this way, at least the bore is machined in a state where the thickness in the disk radial direction at the boundary between the inner side and the outer side is thick, that is, in a high rigidity state, so that deformation due to clamping of the processing machine is prevented, and machining accuracy is improved. Can be improved. Moreover, since machining can be performed with high rigidity, the machining speed can be increased, the machining time can be shortened, and the cost can be reduced.

  According to the invention of claim 2, when the inner side cylinder part, the outer side cylinder part, the inner side torque receiving part, the outer side torque receiving part, and the disk path part are integrally formed by casting, the inner side torque receiving part And the outer side torque receiving part are integrally formed on the inner side in the disk radial direction of the disk path part, and after that, at least the bore is processed, and then the intermediate part is removed by processing, and the inner side torque receiving part And a disc pass recess are formed between the outer torque receiving portion and the outer side torque receiving portion. For this reason, the thickness in the disk radial direction of the boundary portion between the inner side and the outer side at the time of casting becomes thicker due to the interposition part, and as a result, the hot water flow at the time of casting becomes good and the casting accuracy can be improved. In addition, mounting holes that are drilled in at least the outer side cylinder portion in a state where the thickness in the radial direction of the disk in the boundary portion between the inner side and the outer side is thick, that is, in a state where rigidity is high, are orthogonal to the disk axial direction. Therefore, deformation due to the clamp of the processing machine can be prevented and the processing accuracy can be improved. Moreover, since machining can be performed with high rigidity, the machining speed can be increased, the machining time can be shortened, and the cost can be reduced.

  According to the third aspect of the invention, the inner side torque receiving portion, the outer side torque receiving portion, the disc path portion, and the interposition portion are integrally formed by casting between adjacent bores in the disc rotation direction. As a result, the hot water flow in the steel is remarkably improved, and the rigidity after casting is remarkably improved.

An embodiment of the present invention will be described with reference to the drawings.
1 and 2, reference numeral 1 denotes an opposed piston type disc brake. The caliper 11 of the disc brake 1 straddles the disc 12 as shown in FIG. A caliper body 16 attached to the attachment portion 14 of the front fork 13 which is a non-rotating portion, and a plurality of pairs slidably provided on the caliper body 16 so as to face each other via the disk 12, specifically two pairs This is a counter-piston caliper 11 having a piston 17. In the following, description will be given with the mounting state to the vehicle, the radial direction of the disk 12 in this mounting state will be referred to as the disk radial direction, the axial direction of the disk 12 will be referred to as the disk axial direction, and the rotational direction of the disk 12 will be referred to as the disk This is called the direction of rotation. 1 and 2, an arrow R indicates the direction of rotation of the disk 12 when the vehicle moves forward.

  As shown in FIGS. 1 to 3, the caliper body 16 includes an outer cylinder portion 20 disposed on the outer side (opposite side to the wheel) with the disc 12 interposed therebetween, and an inner disposed on the inner side (wheel side). Side cylinder portion 21, a plurality of outer side cylinder portions 20 spaced apart in the disc rotation direction, specifically, outer side torque receiving portions 23 projecting from three positions toward the inner side, and the disc of inner side cylinder portion 21 The inner side torque receiving portion 24 protruding toward the outer side from a plurality of positions separated in the rotational direction, specifically, the outer side torque receiving portion 23 and the inner side torque receiving portion 24 are aligned in the disc rotation direction. It is an integrally molded product having a plurality of, specifically three, disk path portions 26 that connect the objects. That is, the caliper body 16 is provided with an outer side torque receiving portion 23 and an inner side torque receiving portion 24 between the outer side cylinder portion 20 and the inner side cylinder portion 21, and the outer side torque receiving portion 23 and the inner side torque receiving portion 24. A disk path portion 26 is provided between the portions 24 to connect them.

  The caliper body 16 having such a shape has a plurality of portions including an outer side torque receiving portion 23, a disc path portion 26, and an inner side torque receiving portion 24, which are connected in the disc axial direction. Are provided at three locations, and there are a plurality of pad assembling spaces (spaces) 28 opened in the disc radial direction between the adjacent ones in the disc rotation direction, specifically two locations in the disc rotation direction. Is provided.

  On the caliper body 16, pad pins 30 are padded along the disk axial direction between opposing surfaces 20 a, 21 a facing each other through the pad assembly spaces 28 of the outer side cylinder part 20 and the inner side cylinder part 21. It is provided so as to straddle the assembly space 28.

  A bore 31 having a central axis parallel to the disk axial direction is formed at each of the opposing surfaces 20a, 21a facing each other through the pad assembly spaces 28 of the outer cylinder portion 20 and the inner cylinder portion 21. The above-described pistons 17 are fitted into the respective inner diameter portions 32 of the bores 31. As a result, a plurality of pairs, specifically two pairs, of the bores 31 facing in the disk axial direction are formed, and a plurality of pairs of pistons 17 facing in the disk axial direction are formed. There are two pairs.

  Each pad pin 30 of the caliper body 16 supports a total of two pairs of pads 33 movably in the disk axis direction. These pads 33 are arranged on both sides in the axial direction of the disk 12, and are respectively attached to the disks 12 by pistons 17 provided on the caliper body 16 so as to be located on the opposite side of the pads 33 of the pads 33. It is pressed, and thereby a braking force is generated in the vehicle.

  The braking torque at the time of forward braking acts as a force for moving each pad 33 from the disk rotation direction inlet side to the disk rotation direction outlet side, and the force is applied to the caliper body 16 from the pair of pads 33 on the disk rotation direction outlet side. These are transmitted to the caliper body 16 at the outer side torque receiving portion 23 and the inner side torque receiving portion 24 on the most outlet side in the disk rotation direction with which the pads 33 abut, and from the pair of pads 33 on the inlet side in the disk rotation direction to these of the caliper bodies 16. It is transmitted to the caliper body 16 at the outer side torque receiving part 23 and the inner side torque receiving part 24 at the center of the disk rotation direction with which the pad 33 abuts. The braking torque at the time of reverse braking is transmitted from each pad 33 to the caliper body 16 at the outer side torque receiving portion 23 and the inner side torque receiving portion 24 that are in contact with each other on the opposite side to that at the time of forward movement.

  Here, a passage recess 34 shown in FIG. 2 for disposing the disk 12 is formed on the inner side in the disk radial direction of the disk path portion 26 of the caliper body 16, and the outer side torque receiving portion 23 and the inner side are formed. The torque receiving portion 24 extends inward in the disk radial direction from the disk path portion 26 in order to receive torque in the disk rotation direction from the pad 33 arranged at a position overlapping the disk 12 in the disk radial direction. That is, the thickness of the disc path portion 26 in the disc radial direction is thinner than the thickness of the outer side torque receiving portion 23 and the inner side torque receiving portion 24 in the disc radial direction.

  A pad spring 35 for urging the pad 33 inward in the disk radial direction is assembled in the pad assembly space 28 described above.

  The disc brake 1 described above includes a pair of pads 33 arranged on both sides of the disc 12, a caliper body 16 arranged across the disc 12, and a pair of pads 33 in the caliper body 16 opposite to the disc 12. And a piston 17 that is slidably held. A plurality of bores 31 are provided apart from each other in the disk rotation direction, and an inner side torque receiving portion 24, a disk path portion 26, and an outer side torque receiving portion 23 are provided between the adjacent bores 31 in the disk rotation direction. Will be provided.

  The outer cylinder portion 20 of the caliper body 16 has a plurality of specifically two mounting bolt holes 37 for mounting the caliper 11 to the mounting portion 14 of the front fork 13 in parallel with each other along the disk radial direction. Is formed. In addition, the outer cylinder portion 20 of the caliper body 16 has a pipe mounting hole 38 in which a brake pipe is mounted on the outlet side in the disk rotation direction at the time of forward braking, which is an upper position when mounted on the front fork 13. Is formed along the disk axial direction, and a bleeder mounting hole 40 for mounting the air bleeding bleeder plug 39 is formed along the vertical direction at the upper end position above it. In addition, a pad pin hole 41 for attaching the pad pin 30 is formed in the outer cylinder portion 20 and the inner cylinder portion 21 of the caliper body 16 along the disk axial direction.

  In the present embodiment, the caliper body 16 includes the outer cylinder portion 20, the inner cylinder portion 21, all outer torque receiving portions 23, all inner torque receiving portions 24, and all disc path portions 26. Are integrally formed by casting.

  At the time of casting, the core 44 shown in FIGS. 4 to 6 is used. The core 44 in the present embodiment is a shell core obtained by hardening silica sand coated with resin with heat. The core 44 includes a base portion 45 and a plurality of, specifically two, pad assembly space forming portions 46 extending in the same direction at intervals from the base portion 45, and each pad assembly space forming portion. A plurality of bore pilot hole forming portions 47 projecting in opposite directions perpendicular to the arrangement direction of the pad assembling space forming portions 46 from each of the 46 are provided. Each of the bore pilot hole forming portions 47 is a disc provided so as to be coaxial with the cylindrical inner diameter pilot hole forming portion 49 and the pad assembly space forming portion 46 of the inner diameter pilot hole forming portion 49 on the opposite side. And an inner recess forming portion 50. The inner recess forming portion 50 has a larger diameter than the inner diameter prepared hole forming portion 49 and a larger diameter than the inner diameter portion 32 after the inner diameter processing of the bore 31.

  Further, the core 44 includes a communication path forming portion 51 for connecting the adjacent facing positions of the back recess forming portion 50 arranged on the same side, and back recess formation on both sides provided in one pad assembling space forming portion 46. It has the recessed part formation part 52 which protrudes in the radial direction outward from the opposite side to each communicating path formation part 51 of the part 50. As shown in FIG. Each concave portion forming portion 52 has a substantially tapered triangular shape that protrudes while being inclined with respect to the radial direction of the bore pilot hole forming portion 47. In addition, the convex formation part 53 of the shape dented in the surface on the opposite side with respect to the internal diameter pilot hole formation part 49 of each back recess formation part 50 is formed in the center.

  The core 44 is set in a mold 55 schematically shown by a two-dot chain line in FIG. Then, for example, a molten aluminum alloy is poured into a cavity 56 defined by the mold 55 and the core 44. In the cavity 56, the two pad assembling space forming portions 46 are completely separated from each other. Then, after pouring, the mold is released and the core 44 is removed, whereby a cast 16A of the caliper body 16 shown in FIGS. 7 to 15 is obtained.

  The casting 16A of the caliper body 16 is composed of the outer cylinder portion 20 as shown in FIGS. 7, 9, and 10 by the pad assembly space forming portions 46 of the die 55 and the core 44. And the inner side cylinder part 21 facing this is formed. Further, the outer side torque receiving portion 23 protruding toward the inner side from the three positions spaced apart in the disk rotation direction of the outer side cylinder portion 20 and the three positions spaced apart in the disk rotation direction of the inner side cylinder portion 21. Three inner side torque receiving portions 24 projecting from the outer side toward the outer side, and three discs connecting the outer side torque receiving portion 23 and the inner side torque receiving portion 24 aligned in the disc axial direction on the outer side in the disc radial direction A pass portion 26 is formed. The casting 16A includes three interposition portions 58 that connect the outer side torque receiving portion 23 and the inner side torque receiving portion 24 arranged in the disk axial direction inside the disk radial direction of the disk path portion 26, and Two pad assembly spaces 28 are formed between the outer cylinder portion 20 and the inner cylinder portion 21. Here, as shown in FIG. 11, the disc path portion 26 and the interposition portion 58, which are aligned in the disc rotation direction, are integrated in the disc radial direction. Further, as shown in FIGS. 13 to 15, the inner surface 58 </ b> A in the disk radial direction of each interposition portion 58 is a surface 23 </ b> A, 24 </ b> A in the disk radial direction of each of the outer side torque receiving portion 23 and the inner side torque receiving portion 24. It is connected with no steps.

  The two pad assembly spaces 28 described above are formed by the two pad assembly space forming portions 46 of the core 44, but the outer cylinder portion of the casting 16 </ b> A of the caliper body 16. 20, a bore pilot hole (preparation hole) 31 </ b> A is formed by a bore pilot hole forming part 47 protruding from the pad assembly space forming part 46 of the core 44, as shown in FIGS. 10 and 11. . The bore pilot holes 31A are formed at two positions between adjacent ones of the outer side torque receiving portions 23 in the outer side cylinder portion 20 from the opposed surfaces 20A on the inner side cylinder portion 21 side to a predetermined depth. ing.

  In other words, in the outer cylinder portion 20, the cylindrical inner diameter lower hole portion 32 </ b> A of the bore lower hole 31 </ b> A is formed by the inner diameter lower hole forming portion 49 of the core 44. Further, the inner recess 44 of the core 44 has a diameter larger than the inner diameter lower hole 32A and larger than the inner diameter 32 of the processed bore 31 on the inner side of the inner diameter lower hole 32A, that is, on the bottom 61 side. The rear recess portion 60 of the bore prepared hole 31A is formed to be coaxial with the inner diameter prepared hole portion 32A.

  Further, in the outer cylinder portion 20, a convex portion 64 that slightly protrudes in the axial direction is formed by the convex portion forming portion 53 of the core 44 at the time of casting on the bottom surface 59 that constitutes the inner recess portion 60 of each bore pilot hole 31A. Has been.

  Further, in the outer side cylinder portion 20, the inner recesses 60 adjacent to each other in the disk rotation direction are communicated with each other on the adjacent side in the communication passage 62 formed by the communication passage formation portion 51 of the core 44 during casting. As shown in FIG. 12, the recess forming portion 52 has a communication recess 62 that is connected to one of the inner recesses 60 (that is, the bottom 61 side of the bore lower hole 31 </ b> A) on the exit side in the disk rotation direction during forward braking. A concave portion 63 having a generally tapered triangle shape that extends outward in the radial direction while being inclined with respect to the radial direction from the opposite side is formed. The concave portion 63 is located on the outer side in the disk radial direction toward the tip side.

  Similarly, a bore pilot hole 31A is formed in the inner cylinder part 21 of the casting 16A of the caliper body 16 by a bore pilot hole forming part 47 protruding from the pad assembly space forming part 46 of the core 44. . The bore pilot holes 31A are formed at two positions between adjacent ones of the inner side torque receiving portions 24 in the inner side cylinder portion 21 from the opposing surfaces 21A on the outer side cylinder portion 20 side to a predetermined depth. ing.

  In other words, in the inner side cylinder portion 21, the cylindrical inner diameter lower hole portion 32A of the bore lower hole 31A is formed by the inner diameter lower hole forming portion 49 of the core 44. Further, the inner recess 44 of the core 44 has a diameter larger than the inner diameter lower hole 32A and larger than the inner diameter 32 of the processed bore 31 on the inner side of the inner diameter lower hole 32A, that is, on the bottom 61 side. Are formed so as to be coaxial with each inner diameter prepared hole portion 32A.

  Further, in the inner cylinder portion 21, a convex portion 64 that slightly protrudes in the axial direction is formed by a convex portion forming portion 53 of the core 44 at the time of casting on the bottom surface 59 constituting the deep recess portion 60 of each bore pilot hole 31A. Has been.

  Further, in the inner cylinder portion 21, the rear recess portions 60 adjacent to each other in the disk rotation direction are communicated with each other on the proximity facing side in the communication passage 62 formed by the communication passage forming portion 51 of the core 44 during casting. Further, the recess forming portion 52 of the core 44 is positioned on the outer recess portion 60 on the outlet side in the disc rotation direction during forward braking so that the tip end side is located on the outer side in the disc radial direction from the side opposite to the communication path 62. A substantially tapered triangular recess 63 is formed to extend in the vertical direction. That is, in the outer side cylinder portion 20 and the inner side cylinder portion 21, the concave portion 63 is aligned in the disc rotation direction and the disc radial direction.

  The above-described casting 16A of the caliper body 16 has a plurality of bore preparation holes 31A that will be bores 31 later, which are provided apart from each other in the rotation direction of the disk 12, more specifically two places, and adjacent bore preparation holes in the disk rotation direction. Between 31A, the inner side torque receiving part 24, the outer side torque receiving part 23, the disk path part 26, and the interposition part 58 are integrally formed by casting.

  Further, the casting 16A of the caliper body 16 described above is the upper side of the bore lower hole 31A on the outlet side in the disk rotation direction at the time of forward braking which is the uppermost side of the bore lower hole 31A to be the bore 31 when the vehicle body is mounted. A recess 63 is formed on the surface.

  When three or more bores 31 are formed apart from each other in the disk rotation direction, the pad assembling space 28 and bore pilot holes 31A facing it are further added according to the number of the bores 31, and the disk rotation direction is increased. The positions between all the adjacent bore pilot holes 31 </ b> A are communicated by the communication path 62. In this case, the inner side torque receiving portion 24, the outer side torque receiving portion 23, the disk path portion 26, and the interposition portion 58 are integrally formed by casting at all positions between the adjacent bore pilot holes 31A. become. Further, in this case, a recess 63 is formed on the opposite side to the communication path 62 in the inner recess portion 60 which is the most exit side in the disk rotation direction during forward braking and the uppermost side when the vehicle body is mounted.

  The caliper body 16 shown in FIGS. 16 to 26 is obtained by performing the following processing on the casting 16A having the above shape.

  For example, both outer surfaces 20B and 21B which are opposite to the respective disks 12 of the outer side cylinder part 20 and the inner side cylinder part 21 are clamped by a processing machine. At this time, a portion between the outer side torque receiving portion 23 and the inner side torque receiving portion 24 is interposed between the outer side torque receiving portion 23 and the inner side torque by the interposed portion 58 formed on the inner side in the disk radial direction of the disk path portion 26. The receiving portion 24 and the disk radial direction have the same thickness, and the bore side holes 31A adjacent to each other not only at both ends of the outer cylinder portion 20 and the inner cylinder portion 21 in the disk rotation direction but also in the disk rotation direction. Since the outer side torque receiving portion 23, the inner side torque receiving portion 24, the disc path portion 26, and the interposition portion 58 are also provided, the deformation of the casting 16A of the caliper body 16 due to the clamping force is prevented. .

  Then, a tool is inserted into the casting 16A of the caliper body 16 in the clamped state as described above from each pad assembly space 28 between the outer side cylinder portion 20 and the inner side cylinder portion 21. As shown in FIG. 19, FIG. 21, etc., only the inner diameter lower hole portion 32A of the bore lower hole 31A facing the pad assembly space 28 of the outer side cylinder portion 20 and the inner side cylinder portion 21 is cut by a reamer. The inner diameter portion 32 is formed (see the inner diameter prepared hole portion 32A before processing and the inner diameter portion 32 after processing shown in FIG. 26). At the same time, milling is performed to form two seal grooves 66 and 67 in the inner diameter portion 32. That is, all the formed bores 31 include the processed inner diameter portion 32 and the seal grooves 66 and 67 and the inner recess portion 60 which is not processed and remains in the state as cast. The piston 17 is fitted to the inner diameter portion 32 in a state where a seal ring (not shown) is fitted to the seal grooves 66 and 67 at the time of subsequent assembly. Thus, all the bores 31 are processed from the side of the pad assembly space 28 between the inner side cylinder portion 21 and the outer side cylinder portion 20, so that the bottom portions 61 of all the bores 31 are closed during casting. The state is maintained. Note that the convex portion 64 of the back recess portion 60 maintains the piston 17 and the bottom surface 59 in a state where they are always separated from each other even if the piston 17 abuts against this.

  Further, a tool is inserted from each pad assembly space 28 between the outer side cylinder portion 20 and the inner side cylinder portion 21, and each pad assembly of the outer side torque receiving portion 23 and the inner side torque receiving portion 24 is performed. The outer surface shown in FIGS. 16, 18, 19, and 21 that receives the torque from the pad 33 by bringing both end surfaces of the pad 33 in the disk rotation direction into contact with each other by cutting the surface facing the space 28 by milling. The side torque receiving surface 70 and the inner side torque receiving surface 71 are formed.

  Further, a tool is inserted from each pad assembling space 28 between the outer side cylinder portion 20 and the inner side cylinder portion 21 so that the opposing surface 20A of the outer side torque receiving portion 23 and the inner side torque receiving portion 24 face each other. By performing cutting with the milling on the surface 21A, opposing surfaces 20a and 21a facing each other are formed.

  In addition, mounting bolts are inserted into the mounting portion 14 of the front fork 13 so that the outer side cylinder portion 20 passes through the two portions spaced apart in the disk rotation direction at right angles to the disk axial direction and in parallel with each other. 16 and FIG. 18 to FIG. 20 are drilled by boring cutting. Further, the pad pin hole 41 along the disk axial direction is drilled by cutting by boring.

  Further, as shown in FIGS. 20 and 22, a straight passage hole 75 having a bleeder mounting hole 40 on the opening side for mounting the bleeder plug 39 is formed in the disk rotation direction of the outer side cylinder portion 20 of the caliper body 16. Drilling is performed from the outer surface toward the top of the concave portion 63 of the outer cylinder portion 20 by boring, and the bleeder mounting hole 40 is further threaded. Here, since the bleeder mounting hole 40 is disposed on the upper side when the vehicle body is mounted, the passage hole 75 is formed from the outside on the upper side when the vehicle body is mounted so as to communicate with the recess 63.

  In addition, a linear communication hole 76 having a pipe mounting hole 38 for mounting a brake pipe from the master cylinder side on the opening side is described above from the outer surface in the disk axial direction of the outer side cylinder part 20 of the caliper body 16. Drilling is performed to the middle position of the caliper body 16 by cutting by boring while intersecting the passage hole 75 having the bleeder mounting hole 40 in the middle, and the pipe mounting hole 38 is further threaded. Further, it is connected to an intermediate position of the caliper body 16 by boring so as to cross from the outer surface in the disk axial direction of the inner cylinder portion 21 of the caliper body 16 through the recess 63 of the inner cylinder portion 21 and further to the communication hole 76. A hole (passage hole) 77 is formed. The outer surface side of the connection hole 77 is sealed by driving a ball or the like at the time of subsequent assembly.

  As described above, the inner recess portions 60 adjacent to each other in the disk rotation direction of the outer cylinder portion 20, that is, the bores 31 communicate with each other through the communication passage 62, and the inner recess portions 60 adjacent to the inner cylinder portion 21, that is, the bores 31 are also connected. The rear recess 60, that is, the bore 31 on the side where the recess 63 of the outer cylinder 20 is formed is connected to the inner cylinder by the recess 63, the passage hole 75, the communication hole 76, and the connection hole 77. The portion 21 communicates with the inner recess portion 60 on the side where the concave portion 63 is formed, that is, the bore 31. As a result, the bores 31 arranged in the disk rotation direction and all of the bores 31 opposed to the bores 31 in the disk axial direction are all in communication and arranged on one brake fluid flow path. Here, the communication hole 76 having the pipe mounting hole portion 38 and the passage hole 75 and the connection hole 77 intersecting with this constitute a connection path 80 for communicating the bores 31 on both sides in the axial direction of the disk 12. The hole 76 constitutes a part of the connection path 80.

  In this way, all these bores 31 communicate with the pipe mounting hole 38 on the opening side of the communication hole 76, so that the brakes are connected via the brake pipe that will be connected to the communication hole 76 at the time of subsequent assembly. Liquid will be introduced. Further, since all these bores 31 communicate with the bleeder mounting hole 40 on the opening side of the passage hole 75, air is vented from the bleeder plug 39 that is to be mounted in the bleeder mounting hole 40 at the time of subsequent assembly. It will be.

  Then, further necessary processing is performed, and finally, all intervening formed between the outer side torque receiving portion 23 and the inner side torque receiving portion 24 and inside the disc path portion 26 in the radial direction of the disc at the time of casting. 18, 19, 21, and 23 to 25, the portion 58 is removed by milling, and between the inner side torque receiving portion 24 and the outer side torque receiving portion 23, the disk path A passage recess 34 for the disk 12 is formed inside the portion 26 in the disk radial direction. Thereby, between the outer side torque receiving part 23 and the inner side torque receiving part 24, a disk path part 26 having a smaller thickness in the disk radial direction than those connecting the outsides in the disk radial direction is formed. Will be.

  The order of processing is not limited to the above, and it is possible to change the order as appropriate, but at least after processing the inner diameter portion 32 of the bore 31 and the mounting bolt hole 37 that are greatly affected by the clamping force of the processing machine. It is necessary to cut and remove the interposition part 58.

  According to the embodiment described above, when the outer side cylinder portion 20, the inner side cylinder portion 21, the outer side torque receiving portion 23, the inner side torque receiving portion 24, and the disc path portion 26 are integrally formed by casting. The intermediate portion 58 is also integrally formed on the inner side in the disk radial direction of the disk path portion 26 so as to connect the outer side torque receiving portion 23 and the inner side torque receiving portion 24, and thereafter each portion including the inner diameter portion 32 of the bore 31 is formed. After the processing, the interposition portion 58 is removed by processing to form a passage recess 34 for the disk 12 between the outer side torque receiving portion 23 and the inner side torque receiving portion 24. For this reason, the thickness in the disk radial direction of the boundary portion between the inner side and the outer side at the time of casting is increased by the interposition portion 58. As a result, the hot water flow at the time of casting is improved and the casting accuracy can be improved. . Further, in order to machine each part including the inner diameter part 32 of the bore 31 and the mounting bolt hole 37 in a state where the thickness in the disk radial direction of the boundary part between the inner side and the outer side is thick, that is, in a state where rigidity is high, Deformation due to the clamp of the machine can be prevented, and processing accuracy can be improved. Moreover, since machining can be performed with high rigidity, the machining speed can be increased, the machining time can be shortened, and the cost can be reduced.

  In addition, since the outer side torque receiving portion 23, the inner side torque receiving portion 24, the disc path portion 26, and the interposition portion 58 are integrally formed between the adjacent bores 31 in the disk rotation direction by casting, The hot water flow is dramatically improved, and the rigidity after casting is also greatly improved.

It is a front view which shows the disc brake which has the caliper body manufactured by one Embodiment of this invention. It is a side view which shows the disc brake which has the caliper body manufactured by one Embodiment of this invention. It is a perspective view which shows the disc brake which has the caliper body manufactured by one Embodiment of this invention. It is a front view which shows the core used by one Embodiment of this invention. It is a top view which shows the core used by one Embodiment of this invention. It is a left view which shows the core used by one Embodiment of this invention. It is a top view which shows the casting of the caliper body after casting in one Embodiment of this invention. It is a front view which shows the casting of the caliper body after casting in one Embodiment of this invention. It is a bottom view which shows the casting of the caliper body after the casting in one Embodiment of this invention. It is sectional drawing which follows the B1-B1 line | wire of FIG. 8 which shows the casting of the caliper body after the casting in one Embodiment of this invention. It is sectional drawing which follows the A1-A1 line of FIG. 7 which shows the casting of the caliper body after casting in one Embodiment of this invention. It is sectional drawing which follows the A2-A2 line of FIG. 7 which shows the casting of the caliper body after casting in one Embodiment of this invention. It is sectional drawing which follows the C1-C1 line | wire of FIG. 8 which shows the casting of the caliper body after casting in one Embodiment of this invention. It is a left view which shows the casting of the caliper body after the casting in one Embodiment of this invention. It is a right view which shows the casting of the caliper body after the casting in one Embodiment of this invention. It is a top view which shows the caliper body after the process in one Embodiment of this invention. It is a front view which shows the caliper body after the process in one Embodiment of this invention. It is a bottom view which shows the caliper body after the process in one Embodiment of this invention. It is sectional drawing which follows the B2-B2 line | wire of FIG. 17 which shows the caliper body after a process in one Embodiment of this invention. It is sectional drawing which follows the B3-B3 line | wire of FIG. 17 which shows the caliper body after a process in one Embodiment of this invention. It is sectional drawing which follows the A3-A3 line | wire of FIG. 16 which shows the caliper body after a process in one Embodiment of this invention. It is sectional drawing which follows the A4-A4 line | wire of FIG. 16 which shows the caliper body after a process in one Embodiment of this invention. It is sectional drawing which follows the C2-C2 line | wire of FIG. 17 which shows the caliper body after a process in one Embodiment of this invention. It is a left view which shows the caliper body after a process in one Embodiment of this invention. It is a right view which shows the caliper body after a process in one Embodiment of this invention. It is a principal part expanded sectional view which follows the B2-B2 line | wire of FIG. 17 which shows the caliper body after a process in one Embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Disc brake 12 Disc 16 Caliper body 17 Piston 20 Outer side cylinder part 21 Inner side cylinder part 23 Outer side torque receiving part 24 Inner side torque receiving part 26 Disc pass part 31 Bore 33 Pad 34 Passing recess 37 Mounting bolt hole (Mounting hole )
58 Interposition

Claims (3)

A pair of pads are arranged on both sides of a disk, and are used in an opposed piston type disk brake that presses the pair of pads against the disk with pistons arranged on the opposite side of the disk to the disk. An inner side cylinder portion and an outer side cylinder portion each provided with a bore to be movably fitted, and an inner side torque receiver that is between the inner side cylinder portion and the outer side cylinder portion and receives the torque of the pair of pads. A caliper body having a portion and an outer side torque receiving portion, and a disk path portion for connecting the inner side torque receiving portion and the outer side torque receiving portion,
The inner side cylinder part, the outer side cylinder part, the inner side torque receiving part, the outer side torque receiving part, and the disk path part are integrally formed by casting, and the inner side torque receiving part and the An intermediate portion is integrally formed inside the disk path portion in the radial direction of the disk so as to connect the outer side torque receiving portion, and at least after processing the bore, the intermediate portion is removed by processing to remove the inner side torque receiving portion. A caliper body manufacturing method is characterized in that a passage recess of the disk is formed between a portion and the outer side torque receiving portion. A pair of pads are arranged on both sides of a disk, and are used in an opposed piston type disk brake that presses the pair of pads against the disk with pistons arranged on the opposite side of the disk to the disk. An inner side cylinder portion and an outer side cylinder portion each provided with a bore to be movably fitted, and an inner side torque receiver that is between the inner side cylinder portion and the outer side cylinder portion and receives the torque of the pair of pads. A caliper body having a portion and an outer side torque receiving portion, and a disk path portion for connecting the inner side torque receiving portion and the outer side torque receiving portion,
The inner side cylinder part, the outer side cylinder part, the inner side torque receiving part, the outer side torque receiving part, and the disk path part are integrally formed by casting, and the inner side torque receiving part and the An interposition part is integrally formed on the inner side in the disk radial direction of the disk path part so as to connect the outer side torque receiving part, and at least a mounting hole that is formed in the outer side cylinder part and is orthogonal to the disk axial direction is processed. Then, the intermediate portion is removed by machining to form a passage recess for the disk between the inner side torque receiving portion and the outer side torque receiving portion. A plurality of the bores are provided apart from each other in the disc rotation direction, and the inner side torque receiving portion, the outer side torque receiving portion, the disc path portion, and the interposition portion are disposed between adjacent bores in the disc rotation direction. The caliper body manufacturing method according to claim 1, wherein the two are integrally formed by casting.

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