Disc Brake Caliper Half Body Machining for Variable Cylinder Bores
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Solution Overview
Problem
Existing methods require multiple types of casting materials with different cylinder hole diameters and angles for producing caliper half bodies used in disc brake caliper bodies with the same outer shape, leading to increased costs.
Innovation Solution
A method for producing caliper half bodies using the same casting material, involving steps such as introduction hole drilling, cylinder hole cutting, and communication hole cutting, allowing hydraulic fluid introduction and cylinder holes to communicate, even with different diameters, and forming connection holes between adjacent cylinder holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple types of casting materials with different cylinder hole diameters and angles are used to produce caliper half bodies for different disc brake caliper bodies, then the production can accommodate various cylinder hole specifications, but the production cost increases and manufacturing complexity increases
Solution Approach 1:
The patent applies universality by designing a single standardized casting material that can serve multiple functions for producing caliper half bodies across different disc brake caliper body types. The standardized casting material includes a uniform pilot hole configuration that can be adapted to various cylinder hole diameters through post-casting processing, eliminating the need for multiple specialized casting materials for different applications.
Solution Approach 2:
The patent applies parameter changes by maintaining constant parameters in the casting material (such as pilot hole position, angle, and basic geometry) while allowing variable parameters (cylinder hole diameter) to be adjusted through subsequent machining or cutting processes. This separation of fixed and variable parameters enables cost-effective production across multiple product variants.
2Adaptability or versatility
If multiple types of casting materials with different cylinder hole diameters are used, then different disc brake caliper body types can be produced, but the inventory complexity and production preparation time increase
Solution Approach 1:
The standardized casting material serves as a universal base for multiple disc brake caliper body types, functioning as a platform that can be adapted to various specifications through standardized post-processing operations rather than requiring separate specialized materials for each application.
Solution Approach 2:
The patent applies preliminary action by pre-forming the pilot hole in the standardized casting material at the correct position and angle before final cylinder hole creation. This preliminary structuring enables efficient adaptation to different cylinder hole diameters through subsequent cutting or machining operations, reducing overall production complexity.
Data Source
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AI summary
A method for producing a caliper half body, the method involving producing a caliper half body to be used in multiple types of disc brake caliper bodies having different cylinder hole diameters by using the same casting material having a cylinder hole pilot hole, wherein the method comprises: an introduction hole drilling step for forming a first hydraulic fluid introduction hole 11 or a second hydraulic fluid introduction hole 16, through which a hydraulic fluid is introduced into a cylinder hole, in the same casting material by drilling at the same angle from the end surface that will be the joint surface toward the bottom side of the cylinder hole pilot hole; a cylinder hole cutting step for cutting the pilot hole to the established diameter of the cylinder hole; and a connection hole cutting step for forming a connection hole, through which the bottom side of the cut cylinder hole and the first hydraulic fluid introducing hole 11 or the second hydraulic fluid introducing hole 16 are connected, by contouring the bottom side of the cylinder hole.