Floating Disk Brake Caliper Casting Sprue Relocation
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Solution Overview
Problem
The manufacturing efficiency of caliper bodies for floating-type disk brakes is low due to the conventional casting method, which forms cut surfaces at the bottom part of the cylinder, limiting the formation of detailed shapes and increasing the risk of interference with sprues, thus requiring separate countermeasures like additional members for brake pipe connection.
Innovation Solution
A method involving a mold with sprues placed apart in the disk rotor circumferential direction, allowing molten metal to solidify from the cylinder part side, and using riser storage parts to prevent sink marks, while the caliper body is integrally cast with the cylinder, bridge, and claw parts, with sprue cut surfaces on the claw part and riser cut surfaces between them, facilitating better metal flow and reducing turbulent flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the caliper body is cast using the bottom part side of the cylinder part as the sprue, then the casting process is simple, but the manufacturing efficiency becomes low and detailed shapes cannot be formed at the bottom part
Solution Approach 1:
The sprue system is segmented into multiple locations on the claw part rather than using a single sprue at the cylinder bottom. This segmentation allows simultaneous filling of multiple cavity regions, improving manufacturing efficiency while maintaining casting process simplicity
Solution Approach 2:
The sprue locations are moved from the vertical bottom part to the horizontal claw part region. This dimensional relocation allows the sprues to be positioned at multiple circumferential locations, enabling better metal flow distribution and detailed shape formation without compromising ease of manufacture
2Device complexity
If the sprue is located at the bottom part of the cylinder, then the mold design is simple, but the cut surface formation limits detailed shape creation and causes interference with brake pipe connection
Solution Approach 1:
The sprue cut surfaces are extracted from the bottom part of the cylinder and relocated to the claw part. This extraction removes the interference between sprue cut surfaces and brake pipe connection areas, while also enabling detailed shape formation in the bottom part without sprue-related constraints
Solution Approach 2:
The claw part serves as an intermediary region that hosts the sprue cut surfaces. This intermediary location allows the sprues to be positioned away from the cylinder bottom, eliminating interference with brake pipe connections while still providing effective metal flow control for the entire casting
3Reliability
If multiple sprues are provided on the claw part, then metal flow and solidification are improved, but the mold complexity increases
Solution Approach 1:
The claw part region is given multi-functionality by serving as both a structural component of the caliper body and as the location for multiple sprue cut surfaces. This universal use of the claw part region improves metal flow control without requiring additional separate mold components, thus avoiding increased mold complexity
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
This approach improves manufacturing efficiency by allowing the formation of detailed shapes without interference, reducing sink marks, and enhancing castability by ensuring proper metal flow and solidification, thus improving the overall quality and efficiency of caliper body production.
Implementation Method 1
pouring molten metal from the sprues in the at least two places of the mold, the molten metal starting to solidify from a side of the cylinder part
Implementation Method 2
the mold may be disposed so that a region corresponding to the cylinder part is located at a lower side in a vertical direction and a region corresponding to the claw part is located at an upper side in the vertical direction
Data Source
AI summary
A caliper body of a floating-type disk brake includes a cylinder-part constituent part including a cylinder bore into which a piston pressing brake pads against a disk rotor is disposed, a bridge part extending from the cylinder-part constituent part and including a through-hole, and a claw-part constituent part formed on a leading end side of the bridge part and disposed so as to be opposite to the cylinder-part constituent part. In a method of manufacturing the caliper body of the floating-type disk brake, a mold in which sprues are provided in at least two places spaced apart from each other in a disk rotor circumferential direction on a region corresponding to the claw-part constituent part is prepared. Molten metal is poured from the sprues of the at least two places of the mold, and starts to solidify from a side of the cylinder-part constituent part.