The additive manufacturing department of YAMAICHI Special Steel has redesigned the brake calipers.
The manufacturing process used for the redesigned brake caliper is selected laser melting 3D printing technology. The additive manufacturing process releases the design freedom. The redesigned brake caliper can integrate the heat exchange structure on the basis of achieving weight reduction, and increase The oil supply direction of the pressure oil circuit. This design case has certain reference significance for the optimization and innovation of automotive safety component design. This issue of 3D Science Valley will be shared.
Realize weight loss and function integration in limited space
YAMAICHI applied topology optimization technology in the redesign and integrated the TPMS structure for additive manufacturing in the brake caliper. In addition, YAMAICHI added an optimized pressure loss circuit to the design. Considering that the brake caliper may encounter environmental factors such as gravel impact when working, YAMAICHI added a protective surface under the brake caliper to prevent damage from impact.
TPMS is a triple periodic minimum surface (TPMS), and for structural applications, the design shows a high strength-to-weight ratio. If the design is used in conjunction with additive manufacturing technology, it will enable designers to create multi-functional structures with high strength and heat dissipation characteristics.
According to the design scheme disclosed by YAMAICHI, they did design a brake caliper with an integrated heat exchange structure. The function of the heat exchange structure is to cool the brake caliper during the braking cycle. The air flow can pass through the cooling vent and Speed up the cooling process. The caliper with this design is 40% lighter than the traditional design.
Another design innovation of this caliper is the pressure oil circuit. Normally, there is only one direction to supply oil to the caliper piston in the pressure oil circuit, but after the design is optimized, there are five directions to supply oil to the caliper piston. This design helps to produce a better pressure distribution on the piston surface.
When the YAMAICHI team is optimizing the brake caliper, the manufacturing process it faces is an additive manufacturing process based on laser melting of the powder bed. The material is AlSi10Mg.
Exploration of other 3D technology companies
Metal 3D printing technology is mostly used in the manufacture of complex structural parts, but for the manufacture of safety parts such as brake calipers is a field of doubt. However, the 3D printed titanium alloy brake calipers developed by the sports car manufacturer Bugatti and its partners for the Chiron sports car responded strongly to these questions.
Ma Jian, general manager of SLM Solutions Asia Pacific, shared this 3D printed titanium alloy caliper application case, the challenges in design and development, and the final results.
Chiron is one of the most powerful and fastest super sports cars at present, with excellent acceleration performance, acceleration from 0 to 375 km/h, deceleration to 80 km/h requires no more than 42 seconds, and excellent performance is lightweight and The powerful engine puts forward extremely high requirements, and also puts forward higher requirements on the performance of the brake system.
The 3D printed titanium alloy calipers developed by Bugatti and its partners have achieved a good combination of weight reduction, performance, and strength. 3D printed titanium alloy calipers are 41 cm long, 21 cm wide, 13.6 cm high, and weigh only 2.9 kg. Compared with the previously used aluminum parts weighing 4.9 kg, Bugatti can ensure higher strength by using new titanium alloy parts and reduce the weight of the brake caliper by about 40%.
Bugatti 3D printed brake caliper limit test
Bugatti has conducted performance tests on this new 3D printed eight-piston monoblock caliper. 3D printed titanium alloy calipers can handle extreme strength, stiffness and temperature requirements at a speed of 375 km/h. The braking force is 1.35g and the brake disc temperature is up to 1,100°C. The tensile strength of the 3D printed brake caliper is 1250 N/mm2, and the material density exceeds 99.7%. The performance test further reveals the prospect of industrialization of this innovation.