Disk Brake Caliper Friction Stir Welding Inflow Hole Relocation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The application of friction stir welding to calipers with inflow holes at the bottom of the cylinder impairs manufacturing efficiency due to potential interference with the welding tool and reduced flexibility in inflow hole arrangement.
Innovation Solution
A disk-shaped bottom cover member with a protrusion inside the cylinder is integrated via friction stir welding, allowing the inflow hole to be formed within the protrusion, facilitating easier welding and improved manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the inflow hole is formed at the bottom of the cylinder bore, then the fluid pressure supply is achieved, but the friction stir welding process is impaired due to potential interference with the welding tool
Solution Approach 1:
The inflow hole is repositioned from the bottom of the cylinder bore to the side wall of the cylinder bore. This spatial relocation in a different dimension (from axial bottom position to radial side position) eliminates interference with the friction stir welding tool while maintaining fluid pressure supply functionality through the side wall injection
2Reliability
If the inflow hole is formed at the bottom of the cylinder bore, then the fluid pressure supply is achieved, but the welding tool interference reduces manufacturing flexibility
Solution Approach 1:
The inflow hole position is changed from the axial bottom dimension to the radial side wall dimension, providing design flexibility in arranging the inflow hole away from the welding path while maintaining its fluid supply function
3Strength
If friction stir welding is applied to the caliper with bottom-mounted inflow hole, then the caliper components are integrally welded, but the welding process becomes complex and less efficient
Solution Approach 1:
Relocating the inflow hole to the side wall creates clear separation between the welding zone (bottom cover area) and the inflow hole position, allowing friction stir welding to proceed without tool interference while maintaining caliper structural integrity
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 configuration simplifies the friction stir welding process, enhances manufacturing efficiency, and reduces the risk of interference, while maintaining the structural integrity and reliability of the disk brake.
Implementation Method 1
integrally welding the bottom cover member to an opening surrounding portion at the bottom side of the cylinder portion by friction stir welding
Data Source
AI summary
A disk brake and a method of making the disk brake capable of improving the efficiency of manufacturing a caliper. A bottom portion (41) of a bore (40) is formed by integrally welding an opening surrounding portion at the bottom portion side of a cylinder portion (35) and a bottom cover member (92) fitted to the opening surrounding portion by friction stir welding. The bottom cover member is formed into a disk shape, and provided with a protrusion (68) at one surface side facing the interior of the bore. An inflow hole (58), for a supply of a fluid pressure into the bore, is formed within the range of the protrusion to establish communication between an interior surface (71) of the protrusion and an outer surface (63) of the bore.