JP4262417B2 - Caliper body for disc brake for vehicle and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a caliper body for a vehicle disc brake and a manufacturing method thereof.
[0002]
[Prior art]
FIG. 5 shows the configuration of the main part of a disc brake equipped with a hydraulic operating mechanism. In this disc brake, a caliper body main body 10 is provided with a brake hydraulic operating mechanism operated by a brake pedal and a parking brake mechanical operating mechanism operated by a hand lever or a foot pedal. is there. The main body 10 of the caliper body is connected across the outer side of the disk rotor 20 with the action part 10a and the reaction part 10b provided with reaction force claws disposed opposite to both sides of the disk rotor 20, and the action part 10a and the reaction part 10b. And a bridge portion 10c. 20 is a disk rotor, and 12a and 12b are friction pads.
[0003]
The operating portion 10a is provided with a hydraulic cylinder 14, a piston 16 is built in the hydraulic cylinder 14, and a hydraulic chamber is formed between the piston 16 and the bottom of the hydraulic cylinder 14 in a hydraulic chamber. Is done. Reference numeral 18 denotes a parking brake mechanism mounting portion formed on the base side of the hydraulic cylinder 14. The parking brake mechanism mounting portion 18 is a portion formed in a rectangular shape integrally with the action portion 10a, and a parking brake machine such as a cam shaft 19 that is rotated by a wire linked to a hand lever or a foot pedal. A mechanical actuation mechanism is installed.
[0004]
A caliper body used for such a disc brake is manufactured by casting using a material such as iron or aluminum. A general casting method for casting a caliper body is a gravity casting method. A molten mold is injected into a casting mold in which a cavity is formed by combining a plurality of molds such as a core mold, and the molten metal is filled into the cavity. Mold into shape. Actually, after casting the action portion 10a, the reaction portion 10b, and the bridge portion 10c into a predetermined shape using a casting mold, finishing such as grinding processing is performed on a portion where accuracy such as the inner surface of the hydraulic cylinder 14 is required. It is processed into a product.
[0005]
[Problems to be solved by the invention]
Since the caliper body used for the disc brake is manufactured by casting as described above, the outer surface of the caliper body remains a cast surface except for the finished part. Since this cast surface is oxidized to become an oxide film, there arises a problem that the thermal conductivity of the caliper body is lowered and the heat dissipation of the caliper body is hindered.
[0006]
The caliper body made of aluminum is lightweight and has a required strength, and is excellent in thermal conductivity, so that it can be suitably used as a vehicle disc brake. In vehicle disc brakes, high heat is generated due to friction between the disc rotor and the friction material, so manufacturing a caliper body using a material with good thermal conductivity increases the heat dissipation of the caliper body, and the caliper body Prevent overheating. As a result, the inside of the hydraulic cylinder is prevented from becoming high temperature, and the hydraulic fluid that controls the disc brake is prevented from overheating, and a highly reliable brake operation can be performed.
[0007]
However, the cast surface of aluminum is very easy to oxidize, and as it can be seen from the fact that an oxide film is already formed on the surface of the molten metal when it is poured into the casting mold, it was cast using aluminum or an aluminum alloy. The outer surface of the caliper body is covered with an oxide film of aluminum. The casting surface is actually a surface with small irregularities formed so that the aluminum oxide film on the surface of the molten metal is cast on the inner wall surface of the cavity as the molten metal fills the cavity of the casting mold. Become. As a result, an oxide film is formed in a fixed thickness on the casting surface, and this oxide film acts to inhibit the thermal conductivity of the caliper body. For this reason, even if it is the caliper body obtained by casting using the aluminum material excellent in thermal conductivity, sufficient heat dissipation may not be ensured.
[0008]
The present invention has been made to solve the problems associated with the caliper body of a conventional vehicle disc brake manufactured by casting as described above. The object of the present invention is to improve the heat dissipation of the caliper body. An object of the present invention is to provide a caliper body for a disc brake for a vehicle that prevents overheating of hydraulic fluid and the like and enables more reliable brake operation.
[0009]
[Means for Solving the Problems]
In order to achieve the above object, the present invention comprises the following arrangement.
That is, in the caliper body of a vehicle disc brake manufactured by casting, when the outer surface of a part of the main body is cut after casting, the outer surface of the side portion of the bridge portion straddling the disc rotor is cut off, A cutting surface for improving heat dissipation from the bridge portion is formed in the middle of the bridge portion sandwiched between the reaction portions .
Further, in a caliper body of a vehicle disc brake manufactured by casting, when the outer surface of a part of the main body is cut off after casting, the end surface of the parking brake mechanism mounting portion is cut into a flat surface, and the parking brake mechanism mounting portion The cutting surface which improves the heat dissipation from is formed .
Further, in the caliper body before SL disc brake, sites were excised outer surface of the body, it is the site of the body and the sprue portion is connected, by the processing of cutting the sprue portion and the body, the cut edge This is effective in that it can be a heat dissipation surface. Further, in the caliper body of the vehicle disc brake, the product whose body is made of aluminum or aluminum alloy is effective in that a particularly effective heat dissipating action can be exerted by cutting the outer surface of the body. is there.
[0010]
Further, in the method of manufacturing a caliper body for a vehicle disc brake manufactured by casting, when the cast surface covering the outer surface of a part of the main body is cut off after casting, the outer side of the side portion of the bridge portion straddling the disc rotor is removed. The cutting surface which cuts off the surface and improves the heat dissipation from a bridge part is formed in the middle of the bridge part pinched by the action part and the reaction part, It is characterized by the above-mentioned.
Further, in the method of manufacturing a caliper body for a vehicle disc brake manufactured by casting, when the cast surface that covers the outer surface of a part of the main body is cut off after casting, the end surface of the parking brake mechanism mounting portion is made flat. It cuts and forms the cutting surface which improves the heat dissipation from a parking brake mechanism mounting part.
In the method for producing the caliper body of the vehicle disc brake, cast by connecting the site to ablate after casting sprue, the sprue portion you characterized by cutting from the body.
In the caliper body manufacturing method for a vehicle disc brake, the portion for forming the parking brake mechanism mounting portion is the uppermost position in the casting mold, the portion for forming the reaction portion is the lowest position, and the gate is parked. The mechanism mounting portion is connected to a part to be molded, and molten metal is injected into the cavity and cast.
In the method of manufacturing a vehicle disc brake, aluminum or an aluminum alloy is used as a casting material.
[0011]
DETAILED DESCRIPTION OF THE INVENTION
DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, preferred embodiments of the invention will be described in detail with reference to the drawings.
FIG. 1 is an explanatory view showing a method of casting a caliper body of a vehicle disc brake. In the figure, 30a and 30b are upper and lower molds of the casting mold 30, and 32 and 34 are core molds used in combination with the lower mold 30b. By combining the lower mold 30 b and the core molds 32 and 34, a cavity 36 for forming the caliper body main body 10 is formed in the casting mold 30. Reference numeral 38 denotes a feeder part arranged in communication with the cavity 36, and reference numeral 40 denotes a gate.
[0012]
In the illustrated casting mold 30, the cavity 36 is arranged such that the portion 36 a for molding the parking brake mechanism mounting portion 18 of the caliper body main body 10 is the uppermost position in the casting die 30 and the portion 36 b for molding the reaction portion 10 b is formed. As the lowest position, the caliper body main body 10 is vertically arranged in the casting mold 30 and cast. The pouring gate 40 is connected to a portion where the parking brake mechanism mounting portion 18 is formed, and the molten metal is poured from the pouring gate 40 into the cavity 36 through the feeder portion 38 and the parking brake mechanism mounting portion 18 for casting.
[0013]
FIG. 1 shows a state in which molten metal is injected from the gate 40 into the cavity 36 and the cavity 36 and the hot metal portion 38 are filled with the molten metal 50. When the molten metal 50 is filled in the cavity 36, the feeder part 38 reliably fills the cavity 36 with the molten metal 50 by the weight of the molten metal 50 filled in the molten metal part 38, and casts the molten metal The molten metal 50 is replenished in accordance with the volume shrinkage when the 50 is solidified to prevent defects such as sink marks. In the present embodiment, the molten aluminum is poured into the cavity 36 and cast, but the same can be done when casting using a casting material other than aluminum. After the molten metal solidifies in the cavity 36, the mold is opened and the cast product is taken out.
[0014]
2, 3, and 4 are a front view, a side view, and a plan view showing the structure of a caliper body product obtained by subjecting a cast product cast using the casting mold 30 shown in FIG. .
In these figures, 10a is an action part, 10b is a reaction part provided with a reaction force claw, and 10c is a bridge part that connects the action part 10a and the reaction part 10b. A hydraulic cylinder 14 is formed in the action portion 10 a, and a parking brake mechanism mounting portion 18 is formed integrally with the action portion 10 a on the base side of the hydraulic cylinder 14.
[0015]
Since the cast product taken out from the casting mold 30 shown in FIG. 1 is in a state where the metal solidified in the feeder section 38 is connected to the parking brake mechanism mounting portion 18 of the main body 10 of the caliper body, The metal portion solidified in the portion 38 is cut off from the parking brake mechanism mounting portion 18 and removed.
As shown in FIG. 4, the parking brake mechanism mounting portion 18 is a portion formed in a rectangular shape (square column shape), and the metal solidified in the feeder 38 is cut from the parking brake mechanism mounting portion 18. By removing, the end face becomes a cut end face. In the caliper body of this embodiment, the end surface 18a of the parking brake mechanism mounting portion 18 is cut into a flat surface to obtain a cutting surface A. By this cutting process, the cut surface A becomes a glossy surface of aluminum. By making the end surface of the parking brake mechanism mounting portion 18 a cutting surface, it is possible to improve the heat dissipation from the parking brake mechanism mounting portion 18 side.
[0016]
Further, in the caliper body of this embodiment, as shown in FIG. 3, after the cast product is taken out from the casting mold 30, both sides of the bridge portion 10c are cut to cover the outer surface of the main body 10 of the caliper body. The cast surface is removed, and both side surfaces of the bridge portion 10c are defined as cutting surfaces B and B. By this cutting, the cutting surfaces B and B become flat glossy surfaces, and the heat dissipation from the bridge portion 10c can be suitably improved.
As shown in FIG. 3, the cutting surfaces B and B are formed in the middle between the action part 10a and the reaction part 10b. Friction heat due to friction between the disk rotor and the friction material is conducted from the action part 10a and the reaction part 10b to the bridge part 10c, and heat from the disk rotor that becomes high temperature is radiated. Therefore, improving the heat dissipation from the bridge portion 10c is effective in that the deformation due to the heat around the bridge portion 10c can be suppressed.
[0017]
In manufacturing the caliper body, the inner peripheral surface of the hydraulic cylinder 14 is cut after casting, and the union hole and the like connected to the master cylinder are cut. Therefore, the side surface of the bridge portion 10c is cut during these cutting steps. The part can also be cut. Since the bridge portion 10c is processed in the cutting process, there is an advantage that a special processing apparatus is unnecessary and processing can be easily performed. The side surface portion of the bridge portion 10c is a portion exposed to the outside in a flat shape, and can be easily cut.
[0018]
In the present embodiment, in order to improve the heat dissipation from the bridge portion 10c, the side surface of the bridge portion 10c is cut. However, the appropriate portion of the outer surface of the main body 10 other than the bridge portion 10c is cut. As a result, the cast surface on the outer surface can be removed to improve the heat dissipation of the caliper body.
Since the hydraulic cylinder provided in the action part 10a of the caliper body constitutes a hydraulic chamber to which hydraulic fluid is supplied, it is also important to improve the heat dissipation of the hydraulic chamber. This is because the hydraulic chamber is overheated and the hydraulic fluid becomes high temperature and a vapor lock phenomenon may occur. Therefore, it is also effective to cut the outer surface of the caliper body in the vicinity of the hydraulic chamber to remove the cast surface and improve the heat dissipation of the caliper body.
[0019]
As described above, since the parking brake mechanism mounting portion 18 is provided on the bottom side of the hydraulic cylinder in the caliper body of this embodiment, the parking brake mechanism can be obtained by using the end surface of the parking brake mechanism mounting portion 18 as a cutting surface. The heat dissipation from the mounting portion 18 is good, and the heat dissipation of the hydraulic chamber is improved.
Even in the case of a caliper body that does not have a parking brake mechanism mounting part, the cutting end surface becomes a cutting surface at the same time by cutting the pouring part from the connecting part by casting it as an arrangement that connects the pouring part to the bottom side of the hydraulic cylinder. The heat dissipation from the hydraulic chamber can be improved. This is effective in that the process of cutting the sprue portion from the connecting portion and the work of cutting the cut end surface into a cutting surface can be performed simultaneously.
[0020]
The method of improving the heat dissipation of the caliper body by cutting the required part on the outer surface of the caliper body is effective for cast products other than aluminum cast products, but in the case of aluminum cast products, the outer surface of the caliper body In particular, the aluminum oxide film is easily formed, and the heat conduction is hindered by the aluminum oxide film, so that the heat dissipation of the caliper body is suppressed.
[0021]
【The invention's effect】
According to the caliper body of a vehicle disc brake and the method for manufacturing the same according to the present invention, as described above, the casting surface covering the outer surface of the main body is removed by cutting the outer surface of the main body after casting. The heat transfer of the caliper body hindered by the oxide film can be improved, the heat dissipation of the caliper body can be improved, and the caliper body can be prevented from overheating and stable. In addition, a caliper body that enables highly reliable brake operation can be provided.
[Brief description of the drawings]
FIG. 1 is an explanatory view showing a method of manufacturing a caliper body of a vehicle disc brake by casting.
FIG. 2 is a front view showing a configuration of one embodiment of a caliper body of a vehicle disc brake according to the present invention.
FIG. 3 is a side view showing a configuration of one embodiment of a caliper body of a vehicle disc brake according to the present invention.
FIG. 4 is a plan view showing a configuration of an embodiment of a caliper body of a vehicle disc brake according to the present invention.
FIG. 5 is an explanatory view showing a configuration of a main part of a vehicle disc brake.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 Main body 10a Action part 10b Reaction part 10c Bridge part 14 Hydraulic cylinder 16 Piston 18 Parking brake mechanism mounting part 19 Cam shaft 20 Disc rotor 30 Casting mold 30a Upper mold 30b Lower mold 32, 34 Core mold 36 Cavity 38 Feeding part 40 spout 50 molten metal

Claims (9)

In the caliper body of a vehicle disc brake manufactured by casting,
When cutting the outer surface of a part of the main body after casting, cut the outer surface of the side part of the bridge part across the disk rotor,
A caliper body for a vehicle disc brake, wherein a cutting surface for improving heat dissipation from the bridge portion is formed in the middle of the bridge portion sandwiched between the action portion and the reaction portion . In the caliper body of a vehicle disc brake manufactured by casting,
When cutting the outer surface of a part of the main body after casting, the end surface of the parking brake mechanism mounting part is cut into a flat surface to form a cutting surface that improves heat dissipation from the parking brake mechanism mounting part Caliper body for disc brakes for vehicles. In the caliper body of the vehicle disc brake according to claim 1 or 2 ,
A caliper body for a disc brake for a vehicle, wherein a portion of the outer surface of the main body is cut off at a portion where the main body and the gate portion are connected. In the caliper body of the disk brake for vehicles according to any one of claims 1 to 3 ,
A caliper body for a vehicle disc brake, characterized in that the main body is made of aluminum or an aluminum alloy. In a caliper body manufacturing method for a vehicle disc brake manufactured by casting,
After casting, when excising the casting surface covering the outer surface of a part of the main body, the outer surface of the side portion of the bridge portion straddling the disk rotor is excised,
A method for manufacturing a caliper body for a disk brake for a vehicle, wherein a cutting surface for improving heat dissipation from the bridge portion is formed in the middle of the bridge portion sandwiched between the action portion and the reaction portion. In the caliper body manufacturing method for a vehicle disc brake manufactured by casting,
After casting, when cutting the casting surface that covers the outer surface of a part of the main body, the end surface of the parking brake mechanism mounting part is cut into a flat surface, and a cutting surface that improves heat dissipation from the parking brake mechanism mounting part is provided. A method of manufacturing a caliper body for a disc brake for a vehicle, characterized by comprising: In the manufacturing method of the caliper body of the disc brake for vehicles according to claim 5 or 6 ,
A method of manufacturing a caliper body for a vehicle disc brake, wherein a portion to be cut after casting is connected to a gate and casted, and the gate portion is cut from the main body. In the caliper body manufacturing method for a vehicle disc brake according to claim 6,
The part where the parking brake mechanism mounting part is molded is the uppermost position in the casting mold, the part where the reaction part is molded is the lowest position, the gate is connected to the part where the parking mechanism mounting part is molded, and the molten metal is added to the cavity. A method of manufacturing a caliper body for a disc brake for a vehicle, characterized by being cast by casting . 9. The method of manufacturing a caliper body for a vehicle disc brake according to any one of claims 5 to 8, wherein aluminum or an aluminum alloy is used as a casting material.

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