Brake Caliper Casting With Tool Access for Internal Machining
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Solution Overview
Problem
Existing brake caliper manufacturing processes face complications in machining features within and adjacent to the housing that receives an actuating mechanism, as these features are often obscured by an outer portion, making it difficult to form and align machined features like threaded holes and pockets efficiently.
Innovation Solution
The brake caliper design involves casting a single piece with strategically placed holes through the second portion, allowing machining tools to pass through these holes to create threaded holes and pockets without obstruction, and optionally angling the machining tool axis relative to the plane of rotation to access features that would otherwise be inaccessible.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manufacturing processes are used to machine features within and adjacent to the housing, then the housing structure can be maintained, but the machining process becomes complicated and difficult due to obscured access
Solution Approach 1:
The patent applies preliminary action by forming through-holes in the second portion of the housing during the casting process, before any machining operations are performed. This pre-prepared access path allows machining tools to reach features within the housing without obstruction, simplifying subsequent machining operations while maintaining the integrated housing structure.
Solution Approach 2:
The patent utilizes another dimension by creating through-holes that extend through the thickness of the second portion of the housing. This adds a new dimensional pathway (through the housing wall) that allows machining tools to access internal features from the exterior, bypassing the obstruction problem caused by the housing structure itself.
2Manufacturing precision
If machining tools are positioned to access features within the housing, then precise machining can be achieved, but tool alignment and access become difficult due to obscured features
Solution Approach 1:
The through-holes are pre-formed in the housing structure before machining operations, establishing clear access pathways and reference geometries in advance. This preliminary preparation enables machining tools to be precisely aligned with target features through the through-holes, improving both manufacturing precision and ease of tool alignment.
Solution Approach 2:
The through-holes act as intermediaries between the external machining environment and the internal features of the housing. These holes provide a direct transmission pathway that allows machining tools to reach and precisely machine internal features without navigating around obstructions, thereby improving both precision and operational ease.
3Adaptability or versatility
If threaded holes and pockets are formed in the housing, then assembly functionality is enhanced, but the machining process becomes more complex and time-consuming
Solution Approach 1:
The through-holes are created during the casting process, performing the preliminary action of preparing access pathways before any machining occurs. This allows threaded holes and pockets to be machined directly through these pre-formed openings, significantly reducing machining complexity and time while maintaining full assembly functionality.
Solution Approach 2:
By utilizing the through-holes that extend through the housing thickness, the patent creates efficient access pathways for machining threaded holes and pockets. This dimensional approach allows multiple features to be machined in sequence through the same opening, improving productivity by eliminating the need for multiple complex tool approaches while enhancing assembly versatility.
Data Source
AI summary
A brake caliper and method of manufacture. The brake caliper may have a first portion, a second portion, a first bridge and a second bridge that may be provided as a single casting. A first housing side may have a machined feature that may be axially aligned with a hole in the second portion.