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英文原文: Disc Brakes Disc brakes are used on the front wheels of most cars and on all four wheels on many cars. A disc rotor is attached to the wheel hub and rotates with the tire and wheel. When the driver applies the brakes, hydraulic pressure from the master cylinder is used to push friction linings against the rotor to stop it. In the disc brake rotor assembly, the rotor is usually made of cast iron. The hub may be manufactured as one piece with the rotor or in two parts. The rotor has a machined braking surface on each face. A splash shield, mounted to the steering knuckle, protects the rotor from road splash. A rotor may be solid or ventilated. Ventilated designs have cooling fins cast between the braking surfaces. This construction considerably increases the cooling area of the rotor casting. Also, when the wheel is in motion, the rotation of these fan-type fins in the rotor provides increased air circulation and more efficient cooling of the brake. Disc brakes do not fade even after rapid, hard brake applications because of the rapid cooling of the rotor. The hydraulic and friction components are housed in a caliper assembly. The caliper assembly straddles the outside diameter of the hub and rotor assembly. When the brakes are applied, the pressure of the pistons is exerted through the shoes in a ‘clamping’ action on the rotor. Because equal opposed hydraulic pressures are applied to both faces of the rotor throughout application, no distortion of the rotor occurs, regardless of the severity or duration of application. There are many variations of caliper designs, but they can all be grouped into two main categories: moving and stationary caliper. The caliper is fixed in one position on the stationary design. In the moving design, the caliper moves in relation to the rotor. Most late-model cars use the moving caliper design. This design uses a single hydraulic piston and a caliper that can float or slide during application. Floating designs ‘float’ or move on pins or bolts. In sliding designs, the caliper sideways on machined surfaces. Both designs work in basically the same way. In the single piston floating caliper, the single-piston caliper assembly is constructed from a single casting that contains one large piston bore in the inboard section of the casting. In the single piston floating caliper, the single-piston caliper assembly is constructed from a single casting that contains one large piston bore in the inboard section of the casting.Inboard refers to the side of the casting nearest the center line of the car when the caliper is mounted. A fluid inlet hole and bleeder valve hole are machined into the inboard section of the caliper and connect directly to the piston bore. The caliper cylinder bore contains a piston and seal. The seal has a rectangular cross section. It is located in a groove that is machined in the cylinder bore. The seal fits around the outside diameter of the piston and provides a hydraulic seal between the piston and the cylinder wall. The rectangular seal provides automatic adjustment of clearance between the rotor and shoe and linings following each application. When the brakes are applied, the caliper seal is deflected by the hydraulic pressure and its inside diameter rides with the piston within the limits of its retention in the cylinder groove. When hydraulic pressure is released, the seal relaxes and returns to its original rectangular shape, retracting the piston into the cylinder enough to provide proper running clearance. As brake linings wear, piston travel tends to exceed the limit of deflection of the seal; the piston therefore slides in the seal to the precise extent necessary to compensate for lining wear. The top of the piston bore is machined to accept a sealing dust boot. The piston in many calipers is steel, precision ground, and nickel chrome plated, giving it a very hard and durable surface. Some manufacturers are using a plastic piston. This is much lighter than steel and provides for a much lighter brake system. The plastic piston insulates well and prevents heat from transferring to the brake fluid. Each caliper contains two shoe and lining assemblies. They are constructed of a stamped metal shoe with the lining riveted or bonded to the shoe and are mounted in the caliper on either side of the rotor. One shoe and lining assembly is called the inboard lining because it fits nearest to the center line of the car. The other is called the outboard shoe and lining assembly. As already mentioned, the caliper is free to float on its two mounting pins or bolts. Teflon sleeves in the caliper allow it to move easily on the pins. During application of the brakes, the fluid pressure behind the piston increases. Pressure is exerted equally against the bottom of the piston and the bottom of the cylinder bore. The pressure applied to the piston is transmitted to the inboard shoe and lining, forcing the lining against the inboard rotor surface. The pressure applied to the bottom of the cylinder bore forces the caliper to move on the mounting bolts toward the inboard side, or toward the air. Because the caliper is one piece, this movement causes the outboard section of the caliper to apply pressure against the back of the outboard shoe and lining assembly, forcing the lining against the outboard rotor surface. As the line pressure builds up, the shoe and lining assemblies are pressed against the rotor surfaces with increased force, bringing the car to a stop. The application and release of the brake pressure actually causes a very slight movement of the piston and caliper. Upon release of the braking effort, the piston and caliper merely relax into a released position. In the released position, the shoes do not retract very far from the rotor surfaces. 外文翻譯： 盤式制動器 許多汽車所有四個車輪，盤式制動器是用在大多數(shù)轎車的前輪上。制動盤安裝在輪轂上隨著輪胎和車輪轉動。當汽車制動時，液壓主缸推動摩擦片使其停止轉動。 在盤式制動器的轉動部件中，制動盤通常是使用鑄鐵制造。輪轂和制動盤可制造為一體或兩部分。制動盤的每個面都要加工為制動表面。一塊防護板，安裝在轉向節(jié)上，保護制動盤不被飛濺物污染。 制動盤可以是實心或有通風孔。擁有通風孔的制動盤表面之間設有散熱片。這種結構大大提高了制動盤的散熱面積。此外，當車輪在運動時，這些風扇型散熱片在制動盤旋轉時增大空氣流通并提供更有效的制動冷卻。盤式制動器不會受熱變形，即使快速、強制制動，原因就是制動盤的快速冷卻。 液壓和摩擦部件都安裝在制動鉗總成中。制動鉗跨越輪轂和制動盤外徑。當制動器作用時，通過活塞推動制動塊在夾緊制動盤的過程中產(chǎn)生壓力。由于在制動過程中液壓壓力等于應用于制動盤兩側，制動盤沒有出現(xiàn)變形，無論過程的壓力多大和持續(xù)時間。也有許多種制動鉗，但他們都可以分為兩大類：移動和固定卡鉗。固定式卡鉗是固定在一個固定的設計位置上。在移動式設計中，制動卡鉗相對于制動盤移動。 大多數(shù)晚期制造的汽車使用移動式卡鉗。在設計中采用一個單獨的液壓活塞和能夠在制動過程中滑動或擺動的卡鉗。在滑動設計中卡鉗在導向銷上移動。在擺動式設計中，卡鉗在垂直表面內擺動。這兩種設計的工作方式基本相同。 在單活塞浮動卡鉗中，單活塞卡鉗大多是由一個單一的鑄件構成，其中包含一個大型鉆孔作為鑄件的內側部分。內側是指卡鉗安裝時靠近汽車鑄件的一面。制動液入口孔和排氣孔的加工成的卡鉗內側部分，直接連接到活塞孔。 制動鉗缸包含一個活塞和密封圈。該密封圈具有矩形截面。它坐落在一個在缸體的加工孔槽。適合的密封活塞周圍的外徑，并提供了活塞與缸壁液壓密封件。長方形的密封圈提供制動盤和制動塊之間的間隙自動調整。當汽車制動時，密封圈在活塞給予的摩擦力作用下變形。當液壓壓力釋放，密封放松，并變回其原來的長方形，回縮進入氣缸的正常運行提供足夠的間隙活塞。由于制動器襯片的磨損，活塞行程往往超過了密封圈地撓度限制。因此，活塞密封圈能夠精確對襯片的磨損進行補償。 加工活塞的頂部孔安裝一個密封防塵罩。在許多卡鉗活塞是鋼制造的，精密研磨，鍍鉻和鎳，給它一個非常艱難和持久的表面。一些制造商使用的是塑料活塞。這遠遠比鋼輕,提供一個更輕的制動系統(tǒng)?；钊乃芰辖^緣良好，并防止傳遞制動液的熱量。每個鉗包含兩個背板和摩擦襯塊組件。他們粘接或鉚接或壓嵌在一起，并在卡鉗中安裝在制動盤的兩側。最接近汽車中心的制動襯塊被稱為內側制動襯塊。另一側稱為外側制動襯塊。 正如已經(jīng)提到的，浮動卡鉗是在兩個導向銷上固定。在汽車制動時，活塞后面的液體壓力增加。壓力施加在活塞的底部和氣缸底部。作用于活塞的壓力傳遞到內側制動襯塊上，迫使制動盤與內側制動塊摩擦。作用于氣缸孔底部的壓力迫使制動卡鉗向著內側端的導向銷移動。由于制動鉗的移動，使外側制動襯塊與制動盤接觸，迫使外側制動襯塊對制動盤摩擦。隨著制動壓力的積累，內外制動塊反相壓緊制動盤，，使汽車停了下來。 制動壓力釋放實際上會產(chǎn)生一個相對活塞和卡鉗非常輕微的運動。在釋放的工程中，活塞及制動卡鉗只是進入到一個放松和釋放的位置。在釋放的位置，制動襯塊從制動盤的表面收回。 英文原文： China's engineers and users also stay in QianPan HouGu on the idea, and, before and after the application of the disc brake is commercial vehicle braking performance increase the optimal scheme. Because HouGu type brake on the temperature, the braking performance is very big, lead to the front axle attenuation disc brakes to bear on the part of the load, cause too much of the disc brake, brake piece of life of overload shorter. For cars in the braking process, because the role of the front, inertial load always takes all the car load 70% 80%, so the front wheel brake force to than the rear wheels. Manufacturers to cut costs, use the front disc brake, rear wheel drum brake mix of matching method. The QianPan HouGu type mixed brake, this is mainly due to the cost considerations. With the rapid development of China's national economy, the average consumer safety and environmental requirements of cars is increasing day by day, the miniature car industry from tiny truck started, the transition to tiny coaches, and then promoted to use tiny cars as transport, become the necessity of historical development; On the other hand, all miniature car companies already will capital and power steering mini car industry, to adapt to the different needs of consumers out mini car products, some private enterprises will also mini car into the breach of the car market as, constantly of price war, make mini car prices have no longer "too high", and began to close to ordinary people. Disc brake caliper disc and main overall type two kinds, modern car on the application of the most caliper disc brake, it is the rotation of the element is brake disc, fixed element is brake caliper. And, according to the brake caliper movement way and can be divided into set caliper disc brake, sliding caliper disc brake caliper disc brake and, including sliding caliper disc brake application more widely. The working principle of caliper disc brake is similar to a bicycle brake, braking process, the brake caliper will brake piece of extrusion to brake disc, along with the brake disc and lining block of the friction between the gradually will fall speed. And sliding caliper disc brake is brake caliper can be relatively brake disc axial sliding; Only in the inside of the brake disc set oil cylinders, and the outside of the brake block is in the grips attached on the body. Disc brakes in use process, also can appear fault, among them the more common wind resistance, underpowered and brake system has noise etc. Disc brake parts of fever in a narrow focus on the brake lining block, the unit and pressure than drum brakes, brake lining large block and clamp body of the piston direct contact with, so the quantity of heat of braking extremely easily to the brake fluid. So, make disc brakes easy to produce gas resistance phenomenon. But, if take corresponding measures, also can prevent air resistance happens. Miniature and affordable in our country are big car market, in recent years the domestic demand expansion drive the car market demand for miniature of the increase. Authorities say China's economy has entered into the platform, the moderate growth will pull the stable growth of car market. Last year, Chinese each enterprise benefits to improve, per capita disposable income increase, cause individual needs to improve the car; Countries carrying out the strategy for western development, to WeiChe market is tremendous potential demand of no doubt. From 0.9 to 1.6 L L, the price is suitable for China's national conditions, suitable for the current status of the development of the China is. Automobile brake clamps body stent is one of important parts, along with the car now design processing development of manufacturing technology, the brake clamps body in support of materials and processing method and so on is also in constant development, identify processing technology and clamping plan and design, attain thus to the automobile brake clamps body stents processing technology further deeper understanding. The main use of the software has Pro/e, ANSYS and CAPP. Pro/E software using 3 d entity the exact modeling, intuitive parts to reproduce the parts, accurate experience design intention, for parts of the process arrangement after help. Pro/E Mechanica module and the software ANSYS software, finite element analysis, combining do analysis processing produces in the process of the maximum displacement and the maximum stress, and the cutting tool for cutting dosages of the size of the choice to provide reliable basis. This topic use CAPP software developed including making the process route and process design, the complete process documents and improve the process of standardization and standardization. Early detection and solve. According to the retrieval, this in processing industries, and no one made the corresponding introduction. Pro/E software can be accurately to establish various large and complex models. ANSYS software in products manufacturing advance found potential problems, but its modeling ability are weak. The two tools combined, foster strengths and circumvent weaknesses, give full play to the advantages of two kinds of software research and development, is the first choice of complex mechanical structure scheme.This is also I choose the two software reasons. Previous engineering personnel with Pro/E complete three dimensions solid parts design, then use to Mechanica parts structure finite element analysis to find the place, and weak structure is improved. And I'm Pro/E, ANSYS will be applied to the design process of parts, make the past only in process actual implementation, can come into the open process defect, process design stage in can and The error after reflects the workpiece machining allowance method to calculate is, by definition, the processing, surface: its smallest machining allowance (Zbmin) are processing parts of two adjacent step freeways will limit of the difference of the minimum size; Its the biggest machining allowance (Zbmax) are processing parts of two adjacent step freeways will limit of the difference of the largest size. Inside surface processing, the minimum machining allowance is processed spares the maximum limit adjacent freeways will step size poor; Its the biggest machining allowance is processing components work of two adjacent step of the difference of the minimum size limit. The assistant time and basic time coincidence method, using the workbench processing center, get the staff in the cutting process completed work, and then, for auxiliary of the area is larger, and the volume of parts and relatively small, so can use one processing DuoGe parts to make the parts, the piece processing time as little as the basis, double the nc machining center area can also arranged four parts. The rotary worktable, two workpiece in processing at the same time, the clamping workpiece, the other two rotating, processing of just install two workpiece. Selection of cutting parameter and the formulation of &fair standards. Choose the right to improve the cutting dosages, cutting efficiency and guarantee the necessary tools durability and economy, ensure machining quality, has the vital role. Reasonable choice when processing cutting dosages should first choose a as far as possible big, secondly, optimizing the back of choice a larger feeding, and the last in the cutting tool durability, process system stiffness, machine tool power under the terms of the license, the rational choice of cutting speed. &fair standards also says time is fixed in a certain technology organization established under the condition of complete unit out products (such as a parts) or a job (such as a process that must be consumed time). &fair standards is not only, also be the measure index productivity arrange production plan, the calculations of the productioncost is an important basis for new or expansion of the factory, is also (or workshop) computing devices and workers number of basis. Brake caliper disc brake the car body is the critical, brake movement is in the grips body on the final. Installed in clamp body on parts and 16 pieces. One of the more important parts: brake caliper piston, piston callipers at the stents, sealing ring, friction piece, brake caliper shaft pins, spring of and purge screw, etc. Studio, brake fluid through the clamp body JinYou mouth will be pressure to brake caliper Detroit, and by the brake friction pressure before the pistons will to block, press the brake disc, and make clamp body in the brake caliper shaft pins, driving the sliding friction, also after pressure brake disc brake, complete action. The car brake disc brake caliper body shape, structure, material complex special for QT450-10, hardness is HB143-217, machining allowance for 3 mm, form and position tolerances stricter requirements. This product is the important parts, and related to China's automobile brake disc importied problem. In the existing gm in machine tool is completed or processing difficult brake caliper body, especially the lumen of processing, tank must determine the process, to ensure the quality of the processing equipment. Because in general on the machine processing, so blank datum positioning to repeated use, the request to have the precise location of the datum plane, this and use machining center is a very big difference. Such as we are in the process of slot PNE480 CNC machine even with pure inside the car, to ensure that slot cavity type, detection is precision with anatomical projection and after adjustment method of projection. Were now being mass production craft ready to work, according to the auto industry "high starting point, large quantities of specialization," the policy, we have identified on the domestic equipment, save funds, and choose the XK6040 CNC milling machine. 外文文獻翻譯: 中國的工程師和用戶還停留在前盤后鼓的理念上，而前、后盤式制動器的應用才是商用車提高制動性能的最佳方案。由于后鼓式制動器在溫度升高后，制動性能衰減很大，導致前軸上盤式制動器承受不應承擔的過多負載，致使盤式制動器的過載，制動片壽命的縮短。因轎車在制動過程中，由于慣性的作用，前輪的負荷通常占汽車全部負荷的70%－80%，所以前輪制動力要比后輪大。生產(chǎn)廠家為了節(jié)省成本，就采用了前輪盤式制動，后輪鼓式制動的混合匹配方式。采用前盤后鼓式混合制動器，這主要是出于成本上的考慮。隨著我國國民經(jīng)濟的快速發(fā)展，普通消費者對汽車安全和環(huán)保要求日益提高，微型汽車行業(yè)從微型貨車起步，過渡到微型客車，再提升到使用微型轎車作為代步工具，成為歷史發(fā)展的必然；另一方面，所有微型汽車企業(yè)已將主要資金和力量轉向微型轎車行業(yè)，推出適應消費者不同需求的微型轎車產(chǎn)品，一些民營企業(yè)也將微型轎車作為進入汽車市場的突破口，不斷的價格大戰(zhàn)，使得微型轎車價格已不再“曲高和寡”，開始貼近普通百姓。 盤式制動器主要有鉗盤式和全盤式兩種，現(xiàn)代汽車上應用最多的就是鉗盤式制動器，它的旋轉元件是制動盤，固定元件是制動鉗。而根據(jù)制動鉗的運動方式又可分為定鉗盤式制動器、滑動鉗盤式制動器和鉗盤式制動器，其中滑動鉗盤式制動器應用更廣。鉗盤式制動器的工作原理就類似于自行車上的剎車，在制動過程中，制動鉗將制動塊擠壓到制動盤上，隨著制動盤和襯塊之間的摩擦逐漸的將速度降下來。而滑動鉗盤式制動器就是制動鉗可以相對制動盤作軸向滑動；只在制動盤的內側設置油缸，而外側的制動塊則附裝在鉗體上。盤式制動器在使用過程中，也會出現(xiàn)故障，其中比較常見的有氣阻、制動力不足和制動時有噪聲等。 盤式制動器的發(fā)熱部位集中在很窄的制動襯塊上，其單位壓力又比鼓式制動器大，制動襯塊和鉗體的活塞直接接觸，因此制動時的熱量極易傳給制動液。這樣，使盤式制動器容易產(chǎn)生氣阻現(xiàn)象。但是，若采取相應的措施，也可防止氣阻現(xiàn)象的發(fā)生。 微型及普及型汽車在我國有很大市場，近年來內需擴大帶動了對微型汽車市場需求量的增加。有關部門認為中國經(jīng)濟已經(jīng)進入適度增長的平臺，這必將拉動汽車市場的穩(wěn)定增長。去年，中國各企業(yè)效益好轉，居民可支配收入增加，致使個人對汽車需求提高；國家實施西部大開發(fā)戰(zhàn)略，對微車市場無疑也是巨大的潛在需求。從0.9L到1.6L，價格適合我國國情,適合正在發(fā)展的中國的現(xiàn)況。汽車制動器鉗體支架是汽車重要零件之一，隨著現(xiàn)在設計加工制造技術的發(fā)展，制動器鉗體支架的材料及加工手段等也在不斷發(fā)展，確定加工工藝與裝夾方案及設計，從而達到對汽車制動器鉗體支架加工工藝進一步更深了解。 主要用到的軟件有Pro/ENGINEER、ANSYS和CAPP。利用Pro/E軟件進行三維實體零件的精確建模,直觀地再現(xiàn)了零件，準確體會設計意圖，為零件以后的工藝安排提供幫助。Pro/E軟件的Mechanica模塊和ANSYS軟件結合起來做有限元分析,分析加工過程中產(chǎn)生的最大位移和最大應力,為切削用量和刀具尺寸的選擇提供可靠的依據(jù)。本課題利用CAPP軟件編制出包括制訂工藝路線和工序設計在內的完整工藝文件，提高了工藝的標準化和規(guī)范化。早發(fā)現(xiàn)并解決。根據(jù)查新檢索，這在加工行業(yè)里，還沒有人作過相應的介紹。 Pro/ E 軟件可以精確地建立各種龐大復雜的模型。ANSYS軟件在產(chǎn)品制造前預先發(fā)現(xiàn)潛在的問題，但它的建模能力比較弱。這2 個工具結合起來,揚長避短, 充分發(fā)揮2 種軟件的優(yōu)勢,是研究開發(fā)復雜機械結構的首選方案。這也是我選擇這兩個軟件的原因。以往工程人員利用Pro/E完成三維實體零件設計，再運用Mechanica對零件結構進行有限元分析，找出結構薄弱的地方，從而進行改進。而我是將Pro/E、ANSYS應用到零件的工藝過程設計當中，使得過去只有在工藝過程的實際實施中，才能暴露出來的工藝缺陷，在工藝設計階段就能夠及本工件采用誤差復映法計算加工余量，其定義是：外表面加工時，其最小加工余量（Zbmin）是被加工零件相鄰兩工步的兩個最小極限尺寸之差;其最大加工余量（Zbmax）是被加工零件相鄰兩工步的兩個最大極限尺寸之差。內表面加工時，其最小加工余量是被加工零件相鄰兩工步的最大極限尺寸之差;其最大加工余量是被加工零件相鄰兩個工步的最小極限尺寸之差。 采用輔助時間與基本時間重合的方法，采用雙工作臺的加工中心，使工作人員在工件切削加工過程中完成輔助工作，另外，因為工作臺的面積比較大，而零件的體積相對來說又很小，所以可以采用一次加工多個零件的辦法，使得零件的單件加工時間盡可能少，經(jīng)查得雙工作臺數(shù)控加工中心的面積可以同時排布四個零件。采用旋轉工作臺，兩個工件在加工的同時，裝夾另外兩個工件，工作臺旋轉，加工剛剛安裝的兩個工件。 切削用量的選擇和工時定額的制定。正確地選擇切削用量，對提高切削效率，保證必要的刀具耐用度和經(jīng)濟性，保證加工質量，具有重要的作用。合理選擇加工時切削用量應該首先選擇一個盡量大的背吃刀量，其次選擇一個較大的進給量，最后在刀具耐用度，工藝系統(tǒng)剛度，機床功率許可的條件下,選擇合理的切削速度。工時定額也稱時間定額是在一定的技術組織條件下制定出來的完成單位產(chǎn)品（例如一個零件）或某項工作（如一個工序）所必須消耗的時間。工時定額不僅是衡量生產(chǎn)率的指標，也是安排生產(chǎn)計劃，計算生產(chǎn)成本的重要依據(jù)，也是新建或擴建工廠（或車間）時計算設備和工人數(shù)量的依據(jù)。 制動鉗體是轎車盤式制動器上的關鍵件，制動動作是在鉗體上最終完成的。安裝在鉗體上的零件有11種共16件。其中比較重要的零件有：制動鉗活塞，制動鉗支架，活塞密封圈，摩擦塊，制動鉗軸銷，彈簧片與放氣螺塞等。工作室，制動液通過鉗體進油口將壓力傳給制動鉗活塞，然后由制動活塞將壓力傳給前摩擦塊，壓緊制動盤，并使鉗體在制動鉗軸銷上滑動，帶動后摩擦，也壓緊制動盤，完成制動動作。轎車盤式制動器制動鉗體外形復雜，結構特殊，材料為QT450-10，硬度為HB143-217，加工余量為3mm，形位公差要求較嚴。該產(chǎn)品是汽車重要零部件，并關系到我國汽車盤式制動器實現(xiàn)國產(chǎn)化的問題。在現(xiàn)有通用機床上完成或加工難度較大的制動鉗體，尤其是內腔槽型的加工，就必須確定合理的工藝流程，采用工裝來保證加工的質量。因為在通用機床上加工，所以毛坯基準面定位要重復使用，就要求有精確的定位基準面，這與用加工中心加工是有很大差異的。如槽型加工我們是在PNE480數(shù)控機床上用單刀精車內腔，來保證槽型精度，檢測是用解剖投影和投影后修正的方法。 目前正進行大批量生產(chǎn)的工藝準備工作，根據(jù)汽車工業(yè)“高起點，大批量，專業(yè)化”的方針，我們確定了立足國內設備，節(jié)省資金投入，選用了XK6040數(shù)控銑床。