Brake Carrier Casting Mold Segmentation for Stress Reduction
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Solution Overview
Problem
Existing brake carrier casting methods result in stress concentration and increased likelihood of defects due to joint lines, which can lead to localized stresses and reduced durability.
Innovation Solution
A brake carrier casting method that avoids joint lines in high-stress regions by using a mold and core configuration with recesses and core surfaces that create smooth, continuous surfaces, reducing the need for large and expensive cores and minimizing stress concentrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional two-half mold casting method is used, then the brake carrier can be manufactured with standard molding processes, but joint lines are created that cause stress concentration and increase the likelihood of casting defects
Solution Approach 1:
The mold is divided into three separate halves (first mold half, second mold half, and third mold half) instead of the traditional two halves. This segmentation allows the joint lines to be positioned away from high-stress regions, specifically placing them on non-critical surfaces while avoiding the internal corners where stress concentration occurs. The three-half mold configuration enables independent positioning of each mold half to optimize joint line placement.
Solution Approach 2:
Different regions of the brake carrier are treated differently regarding joint line placement. High-stress regions (internal corners) are protected from joint lines, while low-stress regions (external surfaces) accept the joint lines. This local quality approach ensures that joint lines appear only where they will not compromise structural integrity or create stress concentration.
2Reliability
If a large core is used to avoid joint lines in high-stress regions, then stress concentration is reduced, but the manufacturing cost increases significantly
Solution Approach 1:
The mold is segmented into three halves, which eliminates the need for large, expensive cores. By dividing the mold, the joint lines can be strategically positioned without requiring core support. This segmentation approach achieves the same protective effect against stress concentration that large cores would provide, but through a more cost-effective molding strategy.
Solution Approach 2:
The third mold half acts as an intermediary element that allows joint lines to be positioned on non-critical surfaces. Instead of using large cores to physically block joint line formation in high-stress areas, the third mold half serves as a mediator that redirects joint line placement to safe zones, achieving the same protective function without the cost and complexity of large cores.
3Ease of manufacture
If joint lines are positioned in high-stress regions, then the molding process is simpler, but the structural integrity of the brake carrier is compromised
Solution Approach 1:
The molding process treats different regions of the brake carrier with different quality requirements. High-stress regions (internal corners) are protected from joint lines to maintain structural integrity, while low-stress regions (external surfaces) accept joint lines to simplify the molding process. This local quality differentiation allows the molding process to remain simple overall while protecting critical areas.
Solution Approach 2:
By segmenting the mold into three halves, the process maintains simplicity while enabling strategic joint line placement. The segmentation allows joint lines to be positioned on non-critical surfaces without complicating the overall molding process, thus preserving structural integrity in high-stress regions while keeping manufacturing straightforward.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces a brake carrier casting with reduced stress concentrations and increased durability by eliminating joint lines in high-stress areas, thereby enhancing the structural integrity and reducing the risk of defects.
Implementation Method 1
Molten material is poured into the casting void and allowed to cool thereby providing the brake carrier casting
Implementation Method 2
Molten material is poured into the casting void and allowed to cool thereby providing the brake carrier casting
Data Source
Figure 1A
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Figure 2
AI summary
A method of making a brake carrier casting the brake carrier casting having a first side portion spaced from a second side portion thereby defining a plane of a brake rotor, and an axis of rotation of a brake rotor, the first side portion being connected to the second side portion by a first bridge, the first side portion being connected to the second side portion by a second bridge spaced from the first bridge, the first side portion, second side portion, first bridge and second bridge defining an opening of the brake carrier casting, the method including the steps of: a) providing a first mold half having a first recess defining at least a part of a radially inner region of the first side portion, at least a part of a radially inner region of the second side portion, at least a part of a radially inner region of the first bridge, and at least a part of a radially inner region of the second bridge, b) providing a second mold half having a second recess defining at least a part of a radially outer region of the first side portion, at least a part of a radially outer region of the second side portion, at least a part of a radially outer region of the first bridge, and at least a part of a radially outer region of the second bridge, the first mold half and second mold half defining a mold, c) providing a first core having a first core surface for defining the brake carrier casting d) assembling the first core into one of the first or second mold halves in a position such that the first core surface defines a part of a surface of the first side portion facing the opening and defines a part of a surface of the first bridge facing the opening e) closing the mold by assembling the first mold half with the second mold half to provide a casting void, pouring molten material into the casting void and allowing the molten material to cool to provide the brake carrier casting.