Disk Brake Caliper Guide Attachment Overlap Casting
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Solution Overview
Problem
The existing disk brake caliper's formability is compromised due to rapid coagulation of the guide attachment part during casting, which deteriorates the molten metal fluidity and affects the caliper's structural integrity and casting process.
Innovation Solution
The caliper design integrates a guide attachment part with the arm part, where the thickness of the guide attachment part overlaps the arm part in the disk axial direction, improving molten metal fluidity and suppressing rapid coagulation, while ensuring the guide attachment part is connected to the cylinder and arm parts through casting, enhancing the caliper's strength and casting formability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the guide attachment part projects from the caliper and is integrally formed during casting, then the cable guide member can be securely attached, but the guide attachment part rapidly coagulates during casting, deteriorating molten metal fluidity and degrading caliper formability
Solution Approach 1:
The guide attachment part is repositioned from a protruding structure to an integrated structure formed within the thickness of the arm part in the disk axial direction. This dimensional reconfiguration allows the guide attachment part to be formed in the casting process without protruding, thereby maintaining molten metal fluidity while ensuring secure attachment of the cable guide member through integral formation with the arm part.
2Reliability
If the guide attachment part is made thicker to ensure secure cable guide member attachment, then attachment reliability improves, but rapid coagulation during casting worsens and molten metal fluidity deteriorates
Solution Approach 1:
The guide attachment part is repositioned from a protruding structure to an integrated structure formed within the thickness of the arm part in the disk axial direction. This dimensional reconfiguration allows the guide attachment part to be formed in the casting process without protruding, thereby maintaining molten metal fluidity while ensuring secure attachment of the cable guide member through integral formation with the arm part.
Data Source
AI summary
Provided is a disk brake having a caliper. The caliper includes a cylinder part disposed at one side in a disk axial direction and having a bore for accommodating a piston, a pair of arm parts extending to both sides of the cylinder part in a disk rotational direction and having ends to which sliding pins are fixed, and a guide attachment part configured to couple the one arm part to the cylinder part and to which a cable guide member is fixed, which are integrally formed with each other. A thickness of the guide attachment part in a disk diameter direction and a thickness of the one arm part in the disk diameter direction at least partially overlap in the disk axial direction.