高剛性卡鉗小空間加工技術之研究

鋁合金卡鉗由二片卡鉗本體螺絲鎖固，接合面易變形影響煞車靈敏度，本研究是進行高剛性一體式多缸體碟式煞車卡鉗本體設計開發，並結合數值控制工具機，開發出創新性小空間製作加工刀具模組技術。首先以整體加工機台形式來探討可行的加工形式，確認卡鉗可使用的加工空間，決定工件的擺放狀態及刀具的進給形式並設計機台結構，再以電腦繪圖軟體繪製卡鉗本體及加工機CAD圖檔，使用電腦3D動畫軟體模擬加工時機台運動狀態，並利用有限元素分析軟體分析加工機及刀具應力應變及位移量，比較各機台之設計及在統一機台重量下之穩定性優劣，另一方面嘗試使用數控工具機(CNC)主軸為加工動力源，分析國內外刀把專利並改良設計可應用在此活塞容納孔洞之加工。決定其刀具加工軸線方向後，使用腦繪圖軟體繪製刀把、零件CAD圖檔，組裝零組件模擬其加工狀態，再使用電腦3D動畫軟體模擬其設計出的刀把加工運動路徑，接著以有限元素分析軟體分析刀把應力應變及位移量，並且找出最大應力負載區，以提供再設計修正之改良參考，並比較出較佳設計之刀把，再以3D列印手法將其立體化。

關鍵字

煞車卡鉗；橫向銑頭；搪孔

並列摘要

Aluminum calipers caliper body by a two-piece solid screw lock brakes affected joints deformation sensitivity, this study is to conduct high rigidity integrated multi-disc brake caliper cylinder body design and development, combined with CNC machine, the development of innovative production processing tool small space machining technology. First, the overall processing machines to explore possible forms of processing forms, confirmation processing space calipers can be used to determine the state of the workpiece and the tool is placed into the design of the machine to form and structure, and then to draw the caliper body computer graphics software and processing machine CAD drawing, 3D animation using computer software to simulate the timing sets the state of motion processing angel head and analysis using finite element analysis software processing machine and tool stress and strain and displacement, comparing the design of each machine in the unity and stability of the weight of the machine pros and cons, on the other hand try to use CNC machine tools (CNC) machining spindle power source, analyze and improve the design of domestic and foreign patent knife can be used in the processing of this piston to accommodate holes. After the decision of its processing tool axis direction, using brain mapping software to draw knife, parts CAD drawing, assembly components to simulate the processing status, and then use a computer to simulate the 3D animation software to design a knife and processing motion path, then the finite element analysis software analysis of stress and strain, and displacement of the knife, and find the maximum stress load area to provide improved redesign reference as amended.