Angle Tool Head With Dual-Direction Cutter for Caliper Cavities
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Solution Overview
Problem
Machining internal features of a monobloc caliper for disc brake assemblies is inefficient due to the obstruction by the bridge beam, requiring significant manipulation of angle head tools and leading to vibration issues and difficulty in achieving fine tolerances, which increases manufacturing time and cost.
Innovation Solution
A machine tool head with a cutter having two co-axial cutting edges and a gear train that allows machining in two directions without reorientation, improving maneuverability and reducing vibration through increased distance between the cutter and spindle, enabling finer tolerances and reduced manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the distance between the cutter and tool actuator is increased to improve maneuverability, then the tool head can access internal surfaces more easily, but vibration of the tool head increases
Solution Approach 1:
The patent introduces an intermediate dimension by adding a extendable arm mechanism between the cutter and actuator. This allows the cutter to reach into the caliper cavity through the bridge beam opening while the actuator remains positioned outside, effectively adding a spatial dimension to the tool configuration that resolves the maneuverability-vibration contradiction.
Solution Approach 2:
The tool head is segmented into distinct functional components: the actuator, the extendable arm mechanism, and the cutter assembly. This segmentation allows each component to be optimized independently - the actuator for stability and the cutter for maneuverability - while the extendable arm serves as a flexible connector that can be adjusted in length and configuration.
2Adaptability or versatility
If the angle head tool is removed and re-orientated between machining directions to machine bearing support surfaces, then all internal surfaces can be accessed, but manufacturing time increases and fine tolerance becomes more difficult to achieve
Solution Approach 1:
The tool head is designed with multi-functionality to perform multiple machining operations without removal. The cutter assembly can machine bearing support surfaces in both the first and second directions, and also machine the rear surface of the bridge beam, eliminating the need for tool removal and re-orientation between these operations.
Solution Approach 2:
The tool head maintains continuous engagement with the workpiece throughout the machining process. The cutter remains positioned within the caliper cavity and continuously machines different surfaces by moving in different directions, eliminating the interruptions and re-orientation time that would occur with tool removal and re-installation.
3Ease of operation
If a ball nose cutter is used to machine bearing support surfaces, then the cutter can reach internal surfaces, but only line contact is achieved making it difficult to achieve required radius and tolerance
Solution Approach 1:
The patent changes the critical parameter of cutter geometry from a ball nose profile to a different cutter configuration that provides broader contact with the bearing support surfaces. This parameter change enables the cutter to achieve the required surface radius and tolerance while still accessing the internal surfaces through the bridge beam opening.
Data Source
AI summary
A machine tool head for machining internal surfaces of a cavity defined by a monobloc caliper for a disc brake assembly. The tool head is an angle head comprising a cutter for machining said internal surfaces and a drive train configured to connect the cutter to an actuator. The cutter comprises a first cutting edge configured for cutting as the tool head is moved in a first direction and a second cutting edge configured for cutting as the tool head is moved in a second direction.