WO2024049380A1 - Caliper production method with additive manufacturing - Google Patents

Caliper production method with additive manufacturing Download PDF

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Publication number
WO2024049380A1
WO2024049380A1 PCT/TR2023/050751 TR2023050751W WO2024049380A1 WO 2024049380 A1 WO2024049380 A1 WO 2024049380A1 TR 2023050751 W TR2023050751 W TR 2023050751W WO 2024049380 A1 WO2024049380 A1 WO 2024049380A1
Authority
WO
WIPO (PCT)
Prior art keywords
caliper
additive manufacturing
manufacturing
caliper body
production
Prior art date
Application number
PCT/TR2023/050751
Other languages
French (fr)
Inventor
Mehmet Özakinci
Rahmi ÜNAL
Original Assignee
Fnss Savunma Si̇stemleri̇ A.Ş.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Fnss Savunma Si̇stemleri̇ A.Ş. filed Critical Fnss Savunma Si̇stemleri̇ A.Ş.
Publication of WO2024049380A1 publication Critical patent/WO2024049380A1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/60—Treatment of workpieces or articles after build-up
    • B22F10/66—Treatment of workpieces or articles after build-up by mechanical means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/008—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of engine cylinder parts or of piston parts other than piston rings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/20—Post-treatment, e.g. curing, coating or polishing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D55/00—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes
    • F16D55/02—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes with axially-movable discs or pads pressed against axially-located rotating members
    • F16D55/22—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes with axially-movable discs or pads pressed against axially-located rotating members by clamping an axially-located rotating disc between movable braking members, e.g. movable brake discs or brake pads
    • F16D55/228—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes with axially-movable discs or pads pressed against axially-located rotating members by clamping an axially-located rotating disc between movable braking members, e.g. movable brake discs or brake pads with a separate actuating member for each side
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/14—Actuating mechanisms for brakes; Means for initiating operation at a predetermined position
    • F16D65/16—Actuating mechanisms for brakes; Means for initiating operation at a predetermined position arranged in or on the brake
    • F16D65/18—Actuating mechanisms for brakes; Means for initiating operation at a predetermined position arranged in or on the brake adapted for drawing members together, e.g. for disc brakes
    • F16D65/183—Actuating mechanisms for brakes; Means for initiating operation at a predetermined position arranged in or on the brake adapted for drawing members together, e.g. for disc brakes with force-transmitting members arranged side by side acting on a spot type force-applying member
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • B22F2003/247—Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2250/00—Manufacturing; Assembly

Definitions

  • the invention relates to a hydraulic service brake caliper mainly used in the automotive industry and to the production of this caliper by the additive manufacturing method.
  • the invention relates to a caliper manufacturing method comprising the steps of producing a monolithic caliper body by additive manufacturing; CNC machining of the inner regions of the piston bearing, and the regions containing the sealing gasket channels; and joining the cover to the caliper body by welding method, bolted assembly, or by forming a geometrically connected structure in the region of the connection area .
  • the brake system is one of the main systems of vehicles and the brake caliper is an important part at this point. It is a hydraulic part that provides the stopping power of the vehicle and supports the pad produced to start pressing the disk in order to produce it, carries the pad, and provides reciprocating movement towards the disk. Combined with modern disk systems, it is one of the most important systems of the vehicle. When you want to stop or slow down the vehicle, the brake caliper must be activated first.
  • the pressurized hydraulic fluid delivered to the caliper allows the pistons in the caliper to move.
  • the pistons are placed in the piston slots in the caliper body. Thanks to the gaskets in the seal seats, when the brake pedal is pressed, the pressurized hydraulic fluid is trapped in the space between the piston and the piston seat.
  • the pressurized hydraulic fluid pushes the pistons and slides over the seals, pushing the brake pads placed opposite each other in the inner region of the caliper body. They mutually exert force on the brake disc mounted with bolts on the rotating wheel hub in proportion to the hydraulic fluid pressure. As a result of this force applied by the pads on the rotating disc, brake torque is generated on the wheel hub depending on the coefficient of friction between the disc and the pad.
  • caliper manufacturing is carried out by conventional methods such as mold manufacturing, casting, and machining. Design processes are carried out by taking into account the principles and procedures of cast manufacturing.
  • the present invention relates to a hydraulic service brake caliper and the production of this caliper by additive manufacturing method, developed to eliminate the above- mentioned disadvantages and to bring new advantages to the relevant technical field.
  • the most important purpose of the invention is that there is no need for bolted connections due to the monolithic structure. By eliminating the need for bolted connection areas, the structure becomes lighter.
  • Another important purpose of the invention is to eliminate the sealing elements used during the assembly of two parts to each other since the fluid channel is made continuous thanks to the monolithic structure.
  • Another important purpose of the invention is to eliminate mold times and costs with additive manufacturing and to eliminate the need for design changes and mold revisions.
  • Another significant purpose of the invention is to join the cover areas on the outer surface of the caliper by the welding method.
  • bolted joining is also possible, taking into account the increase in weight and the use of gaskets.
  • the caliper is produced as a monolith with the additive manufacturing method.
  • On the inner side of the caliper body there are gasket slots for the gaskets that work with fluid (oil, air, etc.) pressure and are placed for sealing purposes in cylindrical structures where the pistons enter.
  • special surface roughness values or a special geometric structure is required to ensure sealing in the gasket contact areas. It is not possible to obtain special geometric structures or high precision surface roughness values with current metal additive manufacturing technologies.
  • the caliper body is manufactured with open-side surfaces, which enables surface treatment of the gasket seats by conventional manufacturing methods.
  • FIGURE -1 Image showing the caliper subject to the invention
  • FIGURE -2 Image showing the inventive caliper disassembled
  • Figure 1-2 shows the caliper produced by additive manufacturing and its details.
  • the body (10) is produced by 3D printing / additive manufacturing method.
  • the monolithic caliper body (10) manufactured by additive manufacturing is differentiated from the designs made for manufacturing by conventional methods as a solution to the problem of not obtaining surface roughness, which is a limitation of additive manufacturing.
  • the outer region of the piston bearings (11) of the caliper (10) is formed into a cover (20).
  • This cover (20) has a caliper oil inlet (21) for the oil to enter the piston bearings (11).
  • connection region (22) is combined with the connection region (22) by welding method to form the connection structure (30).
  • the bolted joining method can also be used.
  • the caliper is produced using additive manufacturing, CNC machining and welding or bolted joining methods.
  • the brake pads (40) are connected to the body (10) in our invention.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Braking Arrangements (AREA)

Abstract

The invention relates to a hydraulic service brake caliper mainly used in the automotive industry and to the production of this caliper by additive manufacturing method. In particular, the invention relates to a caliper manufacturing method comprising the steps of producing a monolithic caliper body (10) by additive manufacturing; CNC machining of the inner regions of the piston bearing (11) and the regions containing the sealing gasket channels (12); and joining the cover (20) to the caliper body (10) by a joining method such as welding, bolted assembly or geometrically connected structure (30) in the region of the connection area (22).

Description

CALIPER PRODUCTION METHOD WITH ADDITIVE MANUFACTURING TECHNICAL FIELD
The invention relates to a hydraulic service brake caliper mainly used in the automotive industry and to the production of this caliper by the additive manufacturing method.
In particular, the invention relates to a caliper manufacturing method comprising the steps of producing a monolithic caliper body by additive manufacturing; CNC machining of the inner regions of the piston bearing, and the regions containing the sealing gasket channels; and joining the cover to the caliper body by welding method, bolted assembly, or by forming a geometrically connected structure in the region of the connection area .
KNOWN STATUS OF THE TECHNIQUE
Within the automotive industry, there are different parts such as design, system, and hardware. The brake system is one of the main systems of vehicles and the brake caliper is an important part at this point. It is a hydraulic part that provides the stopping power of the vehicle and supports the pad produced to start pressing the disk in order to produce it, carries the pad, and provides reciprocating movement towards the disk. Combined with modern disk systems, it is one of the most important systems of the vehicle. When you want to stop or slow down the vehicle, the brake caliper must be activated first.
According to the working principle of the hydraulic brake caliper; The pressurized hydraulic fluid delivered to the caliper allows the pistons in the caliper to move. The pistons are placed in the piston slots in the caliper body. Thanks to the gaskets in the seal seats, when the brake pedal is pressed, the pressurized hydraulic fluid is trapped in the space between the piston and the piston seat. The pressurized hydraulic fluid pushes the pistons and slides over the seals, pushing the brake pads placed opposite each other in the inner region of the caliper body. They mutually exert force on the brake disc mounted with bolts on the rotating wheel hub in proportion to the hydraulic fluid pressure. As a result of this force applied by the pads on the rotating disc, brake torque is generated on the wheel hub depending on the coefficient of friction between the disc and the pad.
In the current technique, caliper manufacturing is carried out by conventional methods such as mold manufacturing, casting, and machining. Design processes are carried out by taking into account the principles and procedures of cast manufacturing.
In the present technique, the limitations of the casting manufacturing method are much more than the additive manufacturing techniques subject to the invention. As a result of these constraints, caliper manufacturing is currently done in two parts, and assembly is completed by bolt connection. Two structures are connected to each other with bolts. In order to make the bolt connection, the structure must grow significantly. In a brake caliper designed according to the casting method, it is not possible to improve the design with methods such as topology optimization due to the high design constraints imposed by the manufacturing method. Topology optimization is based on the principle of removing the regions that are not subject to stress from the volume of the structure within a certain logic. One of the important advantages of the additive manufacturing method is that it allows topology optimization to the maximum extent.
As a result, the need for a new economical, convenient, practical caliper production method for solving the above-mentioned problems existing in the existing technique and the inadequacy of the existing solutions necessitated a development in the relevant technical field. PURPOSE OF INVENTION
The present invention relates to a hydraulic service brake caliper and the production of this caliper by additive manufacturing method, developed to eliminate the above- mentioned disadvantages and to bring new advantages to the relevant technical field.
The most important purpose of the invention is that there is no need for bolted connections due to the monolithic structure. By eliminating the need for bolted connection areas, the structure becomes lighter.
Another important purpose of the invention is to eliminate the sealing elements used during the assembly of two parts to each other since the fluid channel is made continuous thanks to the monolithic structure.
Another important purpose of the invention is to eliminate mold times and costs with additive manufacturing and to eliminate the need for design changes and mold revisions.
Another significant purpose of the invention is to join the cover areas on the outer surface of the caliper by the welding method. As an alternative to the welding method, bolted joining is also possible, taking into account the increase in weight and the use of gaskets.
In the invention in question, the caliper is produced as a monolith with the additive manufacturing method. On the inner side of the caliper body, there are gasket slots for the gaskets that work with fluid (oil, air, etc.) pressure and are placed for sealing purposes in cylindrical structures where the pistons enter. In these housings, special surface roughness values or a special geometric structure (serrated, serrated, serrated) is required to ensure sealing in the gasket contact areas. It is not possible to obtain special geometric structures or high precision surface roughness values with current metal additive manufacturing technologies. In the method of the invention, the caliper body is manufactured with open-side surfaces, which enables surface treatment of the gasket seats by conventional manufacturing methods.
The structural and characteristic features and all advantages of the invention will be more clearly understood by means of the figures given below and the detailed description written with references to these figures, therefore, the evaluation should be made by considering these figures and detailed description.
FIGURES TO HELP UNDERSTAND THE INVENTION
FIGURE -1; Image showing the caliper subject to the invention
FIGURE -2; Image showing the inventive caliper disassembled
REFERENCE NUMBERS
10. Body
11. Piston Bearing
12. Sealing gasket channel
20. Piston Bearing cover
21. Caliper Oil Inlet
22. Connection area
30. Structure of connection
40. Brake Pad DETAILED DESCRIPTION OF THE INVENTION
In this detailed description, the preferred configurations of the caliper produced by additive manufacturing are described only for the purpose of better understanding the subject matter and without any limiting effect.
Figure 1-2 shows the caliper produced by additive manufacturing and its details. In our invention, the body (10) is produced by 3D printing / additive manufacturing method. In the invention, the monolithic caliper body (10) manufactured by additive manufacturing is differentiated from the designs made for manufacturing by conventional methods as a solution to the problem of not obtaining surface roughness, which is a limitation of additive manufacturing. Accordingly, the outer region of the piston bearings (11) of the caliper (10) is formed into a cover (20). This cover (20) has a caliper oil inlet (21) for the oil to enter the piston bearings (11). In this way, an opening is provided that allows CNC machining to obtain the required surface roughness values in the inner areas of the piston bearing (11) where sealing is important, and in the areas where the sealing gasket grooves (12) are located. After CNC machining, the cover (20) and the caliper body (10) are combined with the connection region (22) by welding method to form the connection structure (30). As an alternative to welding, the bolted joining method can also be used. In this way, the caliper is produced using additive manufacturing, CNC machining and welding or bolted joining methods. The brake pads (40) are connected to the body (10) in our invention.
The scope of protection of this application is set out in the claims and cannot be limited to what is described above strictly by way of illustration. It is obvious that a person skilled in the art can demonstrate the novelty set forth in the invention by using similar embodiments and/or can apply this embodiment to other areas with similar purposes used in the relevant art. Therefore, it is obvious that such structures will lack the criterion of novelty and especially the criterion of exceeding the state of the art.

Claims

1- It is about the hydraulic service brake caliper used in the automotive sector and the production of this caliper by the additive manufacturing method the features are; - production of monolithic caliper body (10) by additive manufacturing method,
CNC machining of the inner areas of the piston bearing (11) and the sealing gasket grooves (12), the cover (20) is attached to the caliper body (10) from the connection area (22), through a welding method, bolted assembly, or by forming a geometrically connected structure (30), that it is characterized by the inclusion of process steps.
PCT/TR2023/050751 2022-09-02 2023-07-31 Caliper production method with additive manufacturing WO2024049380A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
TR2022/013703 2022-09-02
TR2022013703 2022-09-02

Publications (1)

Publication Number Publication Date
WO2024049380A1 true WO2024049380A1 (en) 2024-03-07

Family

ID=90098413

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/TR2023/050751 WO2024049380A1 (en) 2022-09-02 2023-07-31 Caliper production method with additive manufacturing

Country Status (1)

Country Link
WO (1) WO2024049380A1 (en)

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3128200A1 (en) * 2015-08-05 2017-02-08 Freni Brembo S.p.A. Caliper body for a disc brake and method for manufacturing said caliper body
WO2017021817A1 (en) * 2015-08-05 2017-02-09 Freni Brembo S.P.A. Caliper body for a disc brake and method for manufacturing a caliper body
GB2555482A (en) * 2016-10-27 2018-05-02 Alcon Components Ltd Colling ducts for disc brake caliper and method of manufacture thereof

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3128200A1 (en) * 2015-08-05 2017-02-08 Freni Brembo S.p.A. Caliper body for a disc brake and method for manufacturing said caliper body
WO2017021817A1 (en) * 2015-08-05 2017-02-09 Freni Brembo S.P.A. Caliper body for a disc brake and method for manufacturing a caliper body
GB2555482A (en) * 2016-10-27 2018-05-02 Alcon Components Ltd Colling ducts for disc brake caliper and method of manufacture thereof

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