Brake Caliper Core Locator Surfaces for Precision Machining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing brake caliper manufacturing processes often require significant machining to achieve precise tolerances, and there is a need to optimize the design of molds to increase the number of calipers that can be cast within a specified size, reducing machining requirements and improving efficiency.
Innovation Solution
A brake caliper mold with a core member that forms a piston bore and tower window, featuring lateral locator forming surfaces which serve as data reference surfaces for subsequent machining, allowing for the production of brake calipers with a rotor space capable of receiving a brake rotor, and a method involving casting and machining to achieve predetermined tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional molding processes are used for brake calipers, then the caliper structure can be formed, but significant machining is required to achieve precise tolerances
Solution Approach 1:
The patent applies preliminary action by incorporating locator forming surfaces directly into the mold core during the molding process. These surfaces create precise reference features on the caliper body before machining begins, eliminating the need to establish datums during subsequent machining operations. This preliminary formation of precision features directly reduces machining time while maintaining tight tolerances.
Solution Approach 2:
The mold core's locator forming surfaces serve a dual function: they form structural features of the caliper and simultaneously create precision datum surfaces for machining. This self-service approach allows the molding process to provide its own machining references, eliminating the need for separate fixture design and setup, thereby reducing overall manufacturing time.
2Productivity
If the mold is designed to accommodate multiple calipers, then production efficiency increases, but the mold size and complexity increase
Solution Approach 1:
The patent segments the mold into multiple identical cavities, each with its own core member featuring locator forming surfaces. This segmentation allows multiple calipers to be produced simultaneously in one molding cycle, increasing productivity. The standardized segmented design actually reduces overall complexity compared to creating a single complex high-precision mold.
Solution Approach 2:
The patent merges multiple caliper production into a single mold assembly, with each cavity independently forming calipers with integrated locator surfaces. This combining of multiple production units into one mold increases efficiency while the modular nature of each cavity keeps individual complexity manageable.
3Productivity
If machining operations are reduced, then manufacturing time decreases, but achieving precise tolerances becomes more difficult
Solution Approach 1:
The locator forming surfaces are created during the molding process itself, establishing precise datum features before machining begins. This preliminary action ensures that when minimal machining is performed, the caliper can still achieve tight tolerances because the reference surfaces are already precisely formed by the mold core.
Solution Approach 2:
The patent replaces the need for complex mechanical machining setup and fixture systems with precision-formed surfaces created during molding. The mold core's locator forming surfaces substitute for what would otherwise require elaborate machining fixtures and alignment procedures, reducing both time and complexity while maintaining precision.
Data Source
AI summary
Brake calipers, molds and method of producing brake calipers are disclosed including a brake caliper mold for molding a brake caliper, the brake caliper mold comprising: a first mold section; a second section half; a core member configured to form a piston bore, the core member comprising: a tower configured to form a tower window in a bridge of the brake caliper and a piston bore extension to form a piston bore of the brake caliper; and four locator forming surfaces located on the tower, each of the four locator forming surfaces configured to form a separate lateral data reference surface on the brake caliper, the lateral data reference surfaces capable of being used for subsequent machining of the brake caliper to predetermined tolerances.