Angle Tool Head With Dual Cutting Edges for Caliper Cavity Machining
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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 difficulties in achieving fine tolerances and high-quality surface finishes, with increased costs and vibration issues.
Innovation Solution
A machine tool head with two co-axial cutting edges and a gear train that allows machining in two directions without reorientation, improving maneuverability and reducing vibration, while maintaining the tool head within the cavity between cutting operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the tool head is removed from the cavity between machining operations to re-orientate, then the tool can machine surfaces in different directions, but the manufacturing time increases and fine tolerance becomes difficult to achieve
Solution Approach 1:
The cutting tool is segmented into two separate cutting edges (first cutting edge and second cutting edge), each configured to cut in a different direction. This allows the tool head to machine surfaces in different directions without removal and re-orientiation, as each cutting edge is dedicated to a specific cutting direction.
Solution Approach 2:
The tool head is designed with multi-functionality by incorporating both first and second cutting edges that can operate in different directions. This universal design enables the single tool head to perform machining operations in multiple directions within the cavity without requiring removal or re-orientiation.
2Ease of operation
If the distance between the cutter and tool actuator is increased to improve manoeuvrability, then the tool can access internal surfaces more easily, but vibration increases which deteriorates surface finish and may damage the cutting tool
Solution Approach 1:
The cutting edges are arranged in different dimensional orientations within the tool head structure. The first cutting edge is positioned for cutting in a first direction while the second cutting edge is positioned for cutting in a second direction, allowing the tool to access and machine internal surfaces in multiple dimensions without requiring excessive tool length that would cause vibration.
3Ease of operation
If a ball nose cutter is used to machine internal surfaces, then the tool can access the cavity, but only line contact is achieved with the surface making it difficult to achieve the required radius and tolerance
Solution Approach 1:
Different cutting edges are optimized for different local machining requirements. The first cutting edge is configured with specific geometry for cutting in the first direction, while the second cutting edge has optimized geometry for cutting in the second direction, allowing each edge to achieve the required surface radius and tolerance for its specific cutting direction.
Data Source
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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 cutting means for machining said internal surfaces and a drive train configured to connect the cutting means to an actuator. The cutting means 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.