CLAIMS(1)localized plastic deformation in the cast iron brake caliper housing, and below a load high enough to cause failure of the cast iron brake caliper by crack initiation.
WHAT IS CLAIMED IS:
1. A method of manufacturing a caliper for a disc brake, the method comprising the acts of: forming a caliper housing of cast iron; and applying a pre-stressing load to the caliper housing, wherein the pre-stressing load is high enough to cause
2. The method of manufacturing a caliper of claim 1, wherein the caliper is a multi-piece caliper.of material creep under the pre-stressing load.
3. The method of manufacturing a caliper of claim 1, wherein the pre- stressing load is maintained over a predetermined period sufficient to permit localized plastic deformation to occur.
4. The method of manufacturing a caliper of claim 3, wherein the pre- stressing load is maintained over a predetermined period which does not exceed a length of time associated with reaching a predetermined maximum permissible % elongation as a result
5. The method of manufacturing a caliper of claim 4, wherein the pre- stressing load is removed after the pre-determined period has expired.one of applied load, load ramp-up rate, load duration, load reduction rate and cast iron brake caliper housing deflection amount; and rejecting a caliper housing if at least one predetermined process specification is exceeded.
6. The method of manufacturing a caliper of claim 5, further comprising the act of: placing the caliper housing into a pre-stressing fixture prior to applying the pre-stressing load.
7. The method of manufacturing a caliper of claim 5, wherein after each of load applying, load maintaining and load removing, the method further comprising the acts of: determining whether a predetermined process specification is exceeded for at least
8. The method of manufacturing a caliper of claim 7, wherein during the load applying, the pre-stressing load is applied to the cast iron brake caliper in the same manner as a braking load is applied to the caliper when in service on a vehicle, and thepre-stressing load is increased in a controlled manner in accordance with a predetermined pre-stressing loading schedule, and during the load removing, the pre-stressing load is decreased in a controlled manner in accordance with a predetermined pre-
9. The method of manufacturing a caliper of claim 8, wherein the load applying act is performed more than one time before the cast iron brake caliper housing is removed from the pre-stressing fixture.unloading schedule is a linear decrease in load from the predetermined maximum pre-stressing load to an unloaded condition.
10. The method of manufacturing a caliper of claim 8, wherein the predetermined pre-stressing loading schedule is a linear increase in load from an unloaded condition to a predetermined maximum pre-stressing load, and the predetermined pre-stressing
11. The method of manufacturing a caliper of claim 10, wherein the applied pre-stressing load is increased from 0 to between 120 kN and 400 kN.levels in the cast iron brake caliper housing high enough to cause plastic elongation in the cast iron, and below a load high enough to cause failure of the cast iron brake caliper by exceeding an ultimate strength of the cast iron.
12. The method of manufacturing a caliper of claim 10, wherein the applied pre-stressing load is increased from 0 to between 250 kN and 300 kN.
13. The method of manufacturing a caliper of claim 10, wherein the applied pre-stressing load is increased from 0 to approximately 255 kN.
14. The method of manufacturing a caliper of claim 10, wherein the applied pre-stressing load is controlled in response to a measured deflection of the caliper housing.
15. The method of manufacturing a caliper of claim 14, wherein the measured deflection of the caliper housing does not exceed 2.9 mm.
16. A method of manufacturing a caliper for a disc brake, the method comprising the acts of: forming a caliper housing of cast iron; and applying a pre-stressing load to the caliper housing, wherein the pre-stressing load is high enough to cause stress
17. A method for improving fatigue life of a cast iron brake caliper by pre- stressing, the method comprising the acts of: inserting a housing of the cast iron brake caliper into a pre-stressing fixture; applying a pre-stressing load to the cast ironbrake caliper housing, wherein the pre-stressing load is high enough to cause localized plastic deformation in the cast iron brake caliper housing, and below a load high enough to cause failure of the cast iron brake caliper by crack initiation;
18. The cast iron brake caliper pre-stressing method of claim 17, further comprising the act of: after each of the load applying, load maintaining and load removing, determining whether a predetermined process specification is exceeded for at least oneof applied load, load ramp-up rate, load duration, load reduction rate and cast iron brake caliper housing deflection amount.
19. The cast iron brake caliper pre-stressing method of claim 17, wherein during the load applying, the pre-stressing load is applied to the cast iron brake caliper in the same manner as a braking load is applied to the caliper when in service on avehicle, and the pre-stressing load is increased in a controlled manner in accordance with a predetermined pre-stressing loading schedule, and during the load removing, the pre-stressing load is decreased in a controlled manner in accordance with a
20. The cast iron brake caliper pre-stressing method of claim 19, wherein the predetermined pre-stressing loading schedule is a linear increase in load from an unloaded condition to a predetermined maximum pre-stressing load, and the predetermined pre-stressing unloading schedule is a linear decrease in load from the predetermined maximum pre-stressing load to an unloaded condition.
21. The cast iron brake caliper pre-stressing method of claim 20, wherein if a predetermined process specification is exceeded during at least one of the load applying, load maintaining and load removing steps, the cast-iron brake caliper is rejected.deformation in the cast iron brake caliper housing, and below a load high enough to cause failure of the cast iron brake caliper by crack initiation, maintaining the pre-stressing load a predetermined period sufficient to permit the localized plastic
22. The cast iron brake caliper pre-stressing method of claim 21, wherein the load applying, load maintaining and load removing steps are performed more than one time before the cast iron brake caliper is removed from the pre-stressing fixture.
23. A disc brake component, comprising: a cast iron brake caliper housing, wherein the cast iron brake caliper housing includes at least one plastically-deformed region.
24. The disc brake component of claim 23, wherein the at least one plastically deformed region is formed by applying a pre-stressing load to the cast iron brake caliper housing, wherein the pre-stressing load is high enough to cause localized plastic
25. A brake caliper pre-stressing apparatus, comprising: a fixture for receiving a cast iron brake caliper for pre-stressing; a pre-stressing force actuator adapted to apply a pre-stressing load to the cast iron brake caliper; a force transfer modulefor transferring a pre-stressing load from a brake actuator side of the cast iron brake caliper to a reaction side of the cast iron brake caliper; at least one sensor for detecting at least one pre-stressing control parameter for feedback control of the
26. The brake caliper pre-stressing apparatus of claim 25, wherein the at least one sensor includes at least one of a caliper deflection sensor and a pre-stressing load sensor.loading schedule includes the steps of: applying the pre-stressing load to the cast iron brake caliper, wherein the pre-stressing load is high enough to cause localized plastic deformation in the cast iron brake caliper housing, and below a load high
27. The brake caliper pre-stressing apparatus of claim 25, wherein the controller is further programmed to control application of the pre-stressing force in accordance with a pre-determined pre-stressing loading schedule, where the pre-stressing
28. A computer product comprising a computer-readable storage medium having stored therein code segments for causing a brake caliper pre-stressing apparatus to pre-stress a cast iron brake caliper in accordance with a pre- stressing loading schedule,the pre-stressing loading schedule including the acts of: applying a pre-stressing load to the cast iron brake caliper, wherein the pre-stressing load is high enough to cause localized plastic deformation in the cast iron brake caliper housing, and below
29. The computer product of claim 28, wherein code segments cause the brake caliper pre-stressing apparatus to maintain the pre-stressing load over a predetermined period sufficient to permit localized plastic deformation to occur.cast iron brake caliper housing deflection amount; and rejecting a caliper housing if at least one predetermined process specification is exceeded.
30. The computer product of claim 29, wherein code segments cause the brake caliper pre-stressing apparatus to remove the pre-stressing load after the pre-determined period has expired.
31. The computer product of claim 30, wherein code segments further include the acts of: determining whether a predetermined process specification is exceeded for at least one of applied load, load ramp-up rate, load duration, load reduction rate and
32. The computer product of claim 31, wherein code segments cause the brake caliper pre-stressing apparatus to increase the pre-stressing load during the load applying in a controlled manner in accordance with a predetermined pre-stressing loadingschedule, and decrease the pre-stressing load during the load removing in a controlled manner in accordance with a predetermined pre- stressing unloading schedule.
33. The computer product of claim 31, wherein code segments cause the brake caliper pre-stressing apparatus to perform the load applying more than one time to the same cast iron brake caliper.is a linear decrease in load from the predetermined maximum pre-stressing load to an unloaded condition.
34. The computer product of claim 32, wherein the predetermined pre-stressing loading schedule is a linear increase in load from an unloaded condition to a predetermined maximum pre-stressing load, and the predetermined pre-stressing unloading schedule
35. The computer product of claim 34, wherein the applied pre-stressing load is increased from 0 to between 120 kN and 400 kN.with a pre-stressing loading schedule, the pre-stressing loading schedule including the acts of: applying a pre-stressing load to the cast iron brake caliper, wherein the pre-stressing load is high enough to cause localized plastic deformation in the
36. The computer product of claim 34, wherein the applied pre-stressing load is increased from 0 to between 250 kN and 300 kN.
37. The computer product of claim 34, wherein the applied pre-stressing load is increased from 0 to approximately 255 kN.
38. A controller for controlling the operation of a brake caliper pre- stressing apparatus, the controller having stored therein code segments for causing a brake caliper pre-stressing apparatus to pre-stress a cast iron brake caliper in accordance
39. A disk brake assembly, comprising: a brake rotor; and a cast iron brake caliper which straddles the brake rotor when in an in-use position, wherein a housing of the cast iron brake includes at least one plastically-deformed region.deformation in the cast iron brake caliper housing, and below a load high enough to cause failure of the cast iron brake caliper by crack initiation, maintaining the pre-stressing load a predetermined period sufficient to permit localized plastic
40. The disk brake assembly of claim 39, wherein the at least one plastically deformed region is formed by applying a pre-stressing load to the cast iron brake caliper housing, wherein the pre-stressing load is high enough to cause localized plastic
On Wednesday, March 23, 2016 at 6:42:07 PM UTC-5, fuller...@hotmail.com wrote:
http://www.google.com/patents/US8423191 http://www.google.com/patents/WO2010107612A1
localized plastic deformation in the cast iron brake caliper housing, and below a load high enough to cause failure of the cast iron brake caliper by crack initiation.CLAIMS(1)
WHAT IS CLAIMED IS:
1. A method of manufacturing a caliper for a disc brake, the method comprising the acts of: forming a caliper housing of cast iron; and applying a pre-stressing load to the caliper housing, wherein the pre-stressing load is high enough to cause
result of material creep under the pre-stressing load.2. The method of manufacturing a caliper of claim 1, wherein the caliper is a multi-piece caliper.
3. The method of manufacturing a caliper of claim 1, wherein the pre- stressing load is maintained over a predetermined period sufficient to permit localized plastic deformation to occur.
4. The method of manufacturing a caliper of claim 3, wherein the pre- stressing load is maintained over a predetermined period which does not exceed a length of time associated with reaching a predetermined maximum permissible % elongation as a
least one of applied load, load ramp-up rate, load duration, load reduction rate and cast iron brake caliper housing deflection amount; and rejecting a caliper housing if at least one predetermined process specification is exceeded.5. The method of manufacturing a caliper of claim 4, wherein the pre- stressing load is removed after the pre-determined period has expired.
6. The method of manufacturing a caliper of claim 5, further comprising the act of: placing the caliper housing into a pre-stressing fixture prior to applying the pre-stressing load.
7. The method of manufacturing a caliper of claim 5, wherein after each of load applying, load maintaining and load removing, the method further comprising the acts of: determining whether a predetermined process specification is exceeded for at
the pre-stressing load is increased in a controlled manner in accordance with a predetermined pre-stressing loading schedule, and during the load removing, the pre-stressing load is decreased in a controlled manner in accordance with a predetermined pre-8. The method of manufacturing a caliper of claim 7, wherein during the load applying, the pre-stressing load is applied to the cast iron brake caliper in the same manner as a braking load is applied to the caliper when in service on a vehicle, and
unloading schedule is a linear decrease in load from the predetermined maximum pre-stressing load to an unloaded condition.9. The method of manufacturing a caliper of claim 8, wherein the load applying act is performed more than one time before the cast iron brake caliper housing is removed from the pre-stressing fixture.
10. The method of manufacturing a caliper of claim 8, wherein the predetermined pre-stressing loading schedule is a linear increase in load from an unloaded condition to a predetermined maximum pre-stressing load, and the predetermined pre-stressing
stress levels in the cast iron brake caliper housing high enough to cause plastic elongation in the cast iron, and below a load high enough to cause failure of the cast iron brake caliper by exceeding an ultimate strength of the cast iron.11. The method of manufacturing a caliper of claim 10, wherein the applied pre-stressing load is increased from 0 to between 120 kN and 400 kN.
12. The method of manufacturing a caliper of claim 10, wherein the applied pre-stressing load is increased from 0 to between 250 kN and 300 kN.
13. The method of manufacturing a caliper of claim 10, wherein the applied pre-stressing load is increased from 0 to approximately 255 kN.
14. The method of manufacturing a caliper of claim 10, wherein the applied pre-stressing load is controlled in response to a measured deflection of the caliper housing.
15. The method of manufacturing a caliper of claim 14, wherein the measured deflection of the caliper housing does not exceed 2.9 mm.
16. A method of manufacturing a caliper for a disc brake, the method comprising the acts of: forming a caliper housing of cast iron; and applying a pre-stressing load to the caliper housing, wherein the pre-stressing load is high enough to cause
brake caliper housing, wherein the pre-stressing load is high enough to cause localized plastic deformation in the cast iron brake caliper housing, and below a load high enough to cause failure of the cast iron brake caliper by crack initiation;17. A method for improving fatigue life of a cast iron brake caliper by pre- stressing, the method comprising the acts of: inserting a housing of the cast iron brake caliper into a pre-stressing fixture; applying a pre-stressing load to the cast iron
one of applied load, load ramp-up rate, load duration, load reduction rate and cast iron brake caliper housing deflection amount.18. The cast iron brake caliper pre-stressing method of claim 17, further comprising the act of: after each of the load applying, load maintaining and load removing, determining whether a predetermined process specification is exceeded for at least
vehicle, and the pre-stressing load is increased in a controlled manner in accordance with a predetermined pre-stressing loading schedule, and during the load removing, the pre-stressing load is decreased in a controlled manner in accordance with a19. The cast iron brake caliper pre-stressing method of claim 17, wherein during the load applying, the pre-stressing load is applied to the cast iron brake caliper in the same manner as a braking load is applied to the caliper when in service on a
pre-stressing unloading schedule is a linear decrease in load from the predetermined maximum pre-stressing load to an unloaded condition.20. The cast iron brake caliper pre-stressing method of claim 19, wherein the predetermined pre-stressing loading schedule is a linear increase in load from an unloaded condition to a predetermined maximum pre-stressing load, and the predetermined
deformation in the cast iron brake caliper housing, and below a load high enough to cause failure of the cast iron brake caliper by crack initiation, maintaining the pre-stressing load a predetermined period sufficient to permit the localized plastic21. The cast iron brake caliper pre-stressing method of claim 20, wherein if a predetermined process specification is exceeded during at least one of the load applying, load maintaining and load removing steps, the cast-iron brake caliper is rejected.
22. The cast iron brake caliper pre-stressing method of claim 21, wherein the load applying, load maintaining and load removing steps are performed more than one time before the cast iron brake caliper is removed from the pre-stressing fixture.
23. A disc brake component, comprising: a cast iron brake caliper housing, wherein the cast iron brake caliper housing includes at least one plastically-deformed region.
24. The disc brake component of claim 23, wherein the at least one plastically deformed region is formed by applying a pre-stressing load to the cast iron brake caliper housing, wherein the pre-stressing load is high enough to cause localized plastic
for transferring a pre-stressing load from a brake actuator side of the cast iron brake caliper to a reaction side of the cast iron brake caliper; at least one sensor for detecting at least one pre-stressing control parameter for feedback control of the25. A brake caliper pre-stressing apparatus, comprising: a fixture for receiving a cast iron brake caliper for pre-stressing; a pre-stressing force actuator adapted to apply a pre-stressing load to the cast iron brake caliper; a force transfer module
loading schedule includes the steps of: applying the pre-stressing load to the cast iron brake caliper, wherein the pre-stressing load is high enough to cause localized plastic deformation in the cast iron brake caliper housing, and below a load high26. The brake caliper pre-stressing apparatus of claim 25, wherein the at least one sensor includes at least one of a caliper deflection sensor and a pre-stressing load sensor.
27. The brake caliper pre-stressing apparatus of claim 25, wherein the controller is further programmed to control application of the pre-stressing force in accordance with a pre-determined pre-stressing loading schedule, where the pre-stressing
the pre-stressing loading schedule including the acts of: applying a pre-stressing load to the cast iron brake caliper, wherein the pre-stressing load is high enough to cause localized plastic deformation in the cast iron brake caliper housing, and below28. A computer product comprising a computer-readable storage medium having stored therein code segments for causing a brake caliper pre-stressing apparatus to pre-stress a cast iron brake caliper in accordance with a pre- stressing loading schedule,
cast iron brake caliper housing deflection amount; and rejecting a caliper housing if at least one predetermined process specification is exceeded.29. The computer product of claim 28, wherein code segments cause the brake caliper pre-stressing apparatus to maintain the pre-stressing load over a predetermined period sufficient to permit localized plastic deformation to occur.
30. The computer product of claim 29, wherein code segments cause the brake caliper pre-stressing apparatus to remove the pre-stressing load after the pre-determined period has expired.
31. The computer product of claim 30, wherein code segments further include the acts of: determining whether a predetermined process specification is exceeded for at least one of applied load, load ramp-up rate, load duration, load reduction rate and
schedule, and decrease the pre-stressing load during the load removing in a controlled manner in accordance with a predetermined pre- stressing unloading schedule.32. The computer product of claim 31, wherein code segments cause the brake caliper pre-stressing apparatus to increase the pre-stressing load during the load applying in a controlled manner in accordance with a predetermined pre-stressing loading
schedule is a linear decrease in load from the predetermined maximum pre-stressing load to an unloaded condition.33. The computer product of claim 31, wherein code segments cause the brake caliper pre-stressing apparatus to perform the load applying more than one time to the same cast iron brake caliper.
34. The computer product of claim 32, wherein the predetermined pre-stressing loading schedule is a linear increase in load from an unloaded condition to a predetermined maximum pre-stressing load, and the predetermined pre-stressing unloading
with a pre-stressing loading schedule, the pre-stressing loading schedule including the acts of: applying a pre-stressing load to the cast iron brake caliper, wherein the pre-stressing load is high enough to cause localized plastic deformation in the35. The computer product of claim 34, wherein the applied pre-stressing load is increased from 0 to between 120 kN and 400 kN.
36. The computer product of claim 34, wherein the applied pre-stressing load is increased from 0 to between 250 kN and 300 kN.
37. The computer product of claim 34, wherein the applied pre-stressing load is increased from 0 to approximately 255 kN.
38. A controller for controlling the operation of a brake caliper pre- stressing apparatus, the controller having stored therein code segments for causing a brake caliper pre-stressing apparatus to pre-stress a cast iron brake caliper in accordance
deformation in the cast iron brake caliper housing, and below a load high enough to cause failure of the cast iron brake caliper by crack initiation, maintaining the pre-stressing load a predetermined period sufficient to permit localized plastic39. A disk brake assembly, comprising: a brake rotor; and a cast iron brake caliper which straddles the brake rotor when in an in-use position, wherein a housing of the cast iron brake includes at least one plastically-deformed region.
40. The disk brake assembly of claim 39, wherein the at least one plastically deformed region is formed by applying a pre-stressing load to the cast iron brake caliper housing, wherein the pre-stressing load is high enough to cause localized plastic
On Wednesday, March 23, 2016 at 6:46:10 PM UTC-5, fuller...@hotmail.com wrote:
On Wednesday, March 23, 2016 at 6:42:07 PM UTC-5, fuller...@hotmail.com wrote:
http://www.google.com/patents/US8423191 http://www.google.com/patents/WO2010107612A1
localized plastic deformation in the cast iron brake caliper housing, and below a load high enough to cause failure of the cast iron brake caliper by crack initiation.CLAIMS(1)
WHAT IS CLAIMED IS:
1. A method of manufacturing a caliper for a disc brake, the method comprising the acts of: forming a caliper housing of cast iron; and applying a pre-stressing load to the caliper housing, wherein the pre-stressing load is high enough to cause
result of material creep under the pre-stressing load.2. The method of manufacturing a caliper of claim 1, wherein the caliper is a multi-piece caliper.
3. The method of manufacturing a caliper of claim 1, wherein the pre- stressing load is maintained over a predetermined period sufficient to permit localized plastic deformation to occur.
4. The method of manufacturing a caliper of claim 3, wherein the pre- stressing load is maintained over a predetermined period which does not exceed a length of time associated with reaching a predetermined maximum permissible % elongation as a
least one of applied load, load ramp-up rate, load duration, load reduction rate and cast iron brake caliper housing deflection amount; and rejecting a caliper housing if at least one predetermined process specification is exceeded.5. The method of manufacturing a caliper of claim 4, wherein the pre- stressing load is removed after the pre-determined period has expired.
6. The method of manufacturing a caliper of claim 5, further comprising the act of: placing the caliper housing into a pre-stressing fixture prior to applying the pre-stressing load.
7. The method of manufacturing a caliper of claim 5, wherein after each of load applying, load maintaining and load removing, the method further comprising the acts of: determining whether a predetermined process specification is exceeded for at
the pre-stressing load is increased in a controlled manner in accordance with a predetermined pre-stressing loading schedule, and during the load removing, the pre-stressing load is decreased in a controlled manner in accordance with a predetermined pre-8. The method of manufacturing a caliper of claim 7, wherein during the load applying, the pre-stressing load is applied to the cast iron brake caliper in the same manner as a braking load is applied to the caliper when in service on a vehicle, and
stressing unloading schedule is a linear decrease in load from the predetermined maximum pre-stressing load to an unloaded condition.9. The method of manufacturing a caliper of claim 8, wherein the load applying act is performed more than one time before the cast iron brake caliper housing is removed from the pre-stressing fixture.
10. The method of manufacturing a caliper of claim 8, wherein the predetermined pre-stressing loading schedule is a linear increase in load from an unloaded condition to a predetermined maximum pre-stressing load, and the predetermined pre-
stress levels in the cast iron brake caliper housing high enough to cause plastic elongation in the cast iron, and below a load high enough to cause failure of the cast iron brake caliper by exceeding an ultimate strength of the cast iron.11. The method of manufacturing a caliper of claim 10, wherein the applied pre-stressing load is increased from 0 to between 120 kN and 400 kN.
12. The method of manufacturing a caliper of claim 10, wherein the applied pre-stressing load is increased from 0 to between 250 kN and 300 kN.
13. The method of manufacturing a caliper of claim 10, wherein the applied pre-stressing load is increased from 0 to approximately 255 kN.
14. The method of manufacturing a caliper of claim 10, wherein the applied pre-stressing load is controlled in response to a measured deflection of the caliper housing.
15. The method of manufacturing a caliper of claim 14, wherein the measured deflection of the caliper housing does not exceed 2.9 mm.
16. A method of manufacturing a caliper for a disc brake, the method comprising the acts of: forming a caliper housing of cast iron; and applying a pre-stressing load to the caliper housing, wherein the pre-stressing load is high enough to cause
iron brake caliper housing, wherein the pre-stressing load is high enough to cause localized plastic deformation in the cast iron brake caliper housing, and below a load high enough to cause failure of the cast iron brake caliper by crack initiation;17. A method for improving fatigue life of a cast iron brake caliper by pre- stressing, the method comprising the acts of: inserting a housing of the cast iron brake caliper into a pre-stressing fixture; applying a pre-stressing load to the cast
one of applied load, load ramp-up rate, load duration, load reduction rate and cast iron brake caliper housing deflection amount.18. The cast iron brake caliper pre-stressing method of claim 17, further comprising the act of: after each of the load applying, load maintaining and load removing, determining whether a predetermined process specification is exceeded for at least
vehicle, and the pre-stressing load is increased in a controlled manner in accordance with a predetermined pre-stressing loading schedule, and during the load removing, the pre-stressing load is decreased in a controlled manner in accordance with a19. The cast iron brake caliper pre-stressing method of claim 17, wherein during the load applying, the pre-stressing load is applied to the cast iron brake caliper in the same manner as a braking load is applied to the caliper when in service on a
pre-stressing unloading schedule is a linear decrease in load from the predetermined maximum pre-stressing load to an unloaded condition.20. The cast iron brake caliper pre-stressing method of claim 19, wherein the predetermined pre-stressing loading schedule is a linear increase in load from an unloaded condition to a predetermined maximum pre-stressing load, and the predetermined
rejected.21. The cast iron brake caliper pre-stressing method of claim 20, wherein if a predetermined process specification is exceeded during at least one of the load applying, load maintaining and load removing steps, the cast-iron brake caliper is
plastic deformation in the cast iron brake caliper housing, and below a load high enough to cause failure of the cast iron brake caliper by crack initiation, maintaining the pre-stressing load a predetermined period sufficient to permit the localized22. The cast iron brake caliper pre-stressing method of claim 21, wherein the load applying, load maintaining and load removing steps are performed more than one time before the cast iron brake caliper is removed from the pre-stressing fixture.
23. A disc brake component, comprising: a cast iron brake caliper housing, wherein the cast iron brake caliper housing includes at least one plastically-deformed region.
24. The disc brake component of claim 23, wherein the at least one plastically deformed region is formed by applying a pre-stressing load to the cast iron brake caliper housing, wherein the pre-stressing load is high enough to cause localized
module for transferring a pre-stressing load from a brake actuator side of the cast iron brake caliper to a reaction side of the cast iron brake caliper; at least one sensor for detecting at least one pre-stressing control parameter for feedback control25. A brake caliper pre-stressing apparatus, comprising: a fixture for receiving a cast iron brake caliper for pre-stressing; a pre-stressing force actuator adapted to apply a pre-stressing load to the cast iron brake caliper; a force transfer
loading schedule includes the steps of: applying the pre-stressing load to the cast iron brake caliper, wherein the pre-stressing load is high enough to cause localized plastic deformation in the cast iron brake caliper housing, and below a load high26. The brake caliper pre-stressing apparatus of claim 25, wherein the at least one sensor includes at least one of a caliper deflection sensor and a pre-stressing load sensor.
27. The brake caliper pre-stressing apparatus of claim 25, wherein the controller is further programmed to control application of the pre-stressing force in accordance with a pre-determined pre-stressing loading schedule, where the pre-stressing
schedule, the pre-stressing loading schedule including the acts of: applying a pre-stressing load to the cast iron brake caliper, wherein the pre-stressing load is high enough to cause localized plastic deformation in the cast iron brake caliper housing,28. A computer product comprising a computer-readable storage medium having stored therein code segments for causing a brake caliper pre-stressing apparatus to pre-stress a cast iron brake caliper in accordance with a pre- stressing loading
and cast iron brake caliper housing deflection amount; and rejecting a caliper housing if at least one predetermined process specification is exceeded.29. The computer product of claim 28, wherein code segments cause the brake caliper pre-stressing apparatus to maintain the pre-stressing load over a predetermined period sufficient to permit localized plastic deformation to occur.
30. The computer product of claim 29, wherein code segments cause the brake caliper pre-stressing apparatus to remove the pre-stressing load after the pre-determined period has expired.
31. The computer product of claim 30, wherein code segments further include the acts of: determining whether a predetermined process specification is exceeded for at least one of applied load, load ramp-up rate, load duration, load reduction rate
schedule, and decrease the pre-stressing load during the load removing in a controlled manner in accordance with a predetermined pre- stressing unloading schedule.32. The computer product of claim 31, wherein code segments cause the brake caliper pre-stressing apparatus to increase the pre-stressing load during the load applying in a controlled manner in accordance with a predetermined pre-stressing loading
schedule is a linear decrease in load from the predetermined maximum pre-stressing load to an unloaded condition.33. The computer product of claim 31, wherein code segments cause the brake caliper pre-stressing apparatus to perform the load applying more than one time to the same cast iron brake caliper.
34. The computer product of claim 32, wherein the predetermined pre-stressing loading schedule is a linear increase in load from an unloaded condition to a predetermined maximum pre-stressing load, and the predetermined pre-stressing unloading
with a pre-stressing loading schedule, the pre-stressing loading schedule including the acts of: applying a pre-stressing load to the cast iron brake caliper, wherein the pre-stressing load is high enough to cause localized plastic deformation in the35. The computer product of claim 34, wherein the applied pre-stressing load is increased from 0 to between 120 kN and 400 kN.
36. The computer product of claim 34, wherein the applied pre-stressing load is increased from 0 to between 250 kN and 300 kN.
37. The computer product of claim 34, wherein the applied pre-stressing load is increased from 0 to approximately 255 kN.
38. A controller for controlling the operation of a brake caliper pre- stressing apparatus, the controller having stored therein code segments for causing a brake caliper pre-stressing apparatus to pre-stress a cast iron brake caliper in accordance
plastic deformation in the cast iron brake caliper housing, and below a load high enough to cause failure of the cast iron brake caliper by crack initiation, maintaining the pre-stressing load a predetermined period sufficient to permit localized plastic39. A disk brake assembly, comprising: a brake rotor; and a cast iron brake caliper which straddles the brake rotor when in an in-use position, wherein a housing of the cast iron brake includes at least one plastically-deformed region.
40. The disk brake assembly of claim 39, wherein the at least one plastically deformed region is formed by applying a pre-stressing load to the cast iron brake caliper housing, wherein the pre-stressing load is high enough to cause localized
Approx. Webbing Volume 16 cm x 16 cm x 1 cm x two webs = 512 cm^3
4.0 * 10^10 dynes
400,000 Newtons
kilogram per cubic centimeter (kg/cm³) 0.00787
512 cm^3 * 0.00787 kg = 4.02944 kg
(400 000 newtons) * 4.02944 kilograms = 1.61 * 10^6 Joules
On Wednesday, March 23, 2016 at 6:57:31 PM UTC-5, fuller...@hotmail.com wrote:
On Wednesday, March 23, 2016 at 6:46:10 PM UTC-5, fuller...@hotmail.com wrote:
On Wednesday, March 23, 2016 at 6:42:07 PM UTC-5, fuller...@hotmail.com wrote:
http://www.google.com/patents/US8423191 http://www.google.com/patents/WO2010107612A1
localized plastic deformation in the cast iron brake caliper housing, and below a load high enough to cause failure of the cast iron brake caliper by crack initiation.CLAIMS(1)
WHAT IS CLAIMED IS:
1. A method of manufacturing a caliper for a disc brake, the method comprising the acts of: forming a caliper housing of cast iron; and applying a pre-stressing load to the caliper housing, wherein the pre-stressing load is high enough to cause
result of material creep under the pre-stressing load.2. The method of manufacturing a caliper of claim 1, wherein the caliper is a multi-piece caliper.
3. The method of manufacturing a caliper of claim 1, wherein the pre- stressing load is maintained over a predetermined period sufficient to permit localized plastic deformation to occur.
4. The method of manufacturing a caliper of claim 3, wherein the pre- stressing load is maintained over a predetermined period which does not exceed a length of time associated with reaching a predetermined maximum permissible % elongation as a
least one of applied load, load ramp-up rate, load duration, load reduction rate and cast iron brake caliper housing deflection amount; and rejecting a caliper housing if at least one predetermined process specification is exceeded.5. The method of manufacturing a caliper of claim 4, wherein the pre- stressing load is removed after the pre-determined period has expired.
6. The method of manufacturing a caliper of claim 5, further comprising the act of: placing the caliper housing into a pre-stressing fixture prior to applying the pre-stressing load.
7. The method of manufacturing a caliper of claim 5, wherein after each of load applying, load maintaining and load removing, the method further comprising the acts of: determining whether a predetermined process specification is exceeded for at
and the pre-stressing load is increased in a controlled manner in accordance with a predetermined pre-stressing loading schedule, and during the load removing, the pre-stressing load is decreased in a controlled manner in accordance with a predetermined8. The method of manufacturing a caliper of claim 7, wherein during the load applying, the pre-stressing load is applied to the cast iron brake caliper in the same manner as a braking load is applied to the caliper when in service on a vehicle,
stressing unloading schedule is a linear decrease in load from the predetermined maximum pre-stressing load to an unloaded condition.9. The method of manufacturing a caliper of claim 8, wherein the load applying act is performed more than one time before the cast iron brake caliper housing is removed from the pre-stressing fixture.
10. The method of manufacturing a caliper of claim 8, wherein the predetermined pre-stressing loading schedule is a linear increase in load from an unloaded condition to a predetermined maximum pre-stressing load, and the predetermined pre-
stress levels in the cast iron brake caliper housing high enough to cause plastic elongation in the cast iron, and below a load high enough to cause failure of the cast iron brake caliper by exceeding an ultimate strength of the cast iron.11. The method of manufacturing a caliper of claim 10, wherein the applied pre-stressing load is increased from 0 to between 120 kN and 400 kN.
12. The method of manufacturing a caliper of claim 10, wherein the applied pre-stressing load is increased from 0 to between 250 kN and 300 kN.
13. The method of manufacturing a caliper of claim 10, wherein the applied pre-stressing load is increased from 0 to approximately 255 kN.
14. The method of manufacturing a caliper of claim 10, wherein the applied pre-stressing load is controlled in response to a measured deflection of the caliper housing.
15. The method of manufacturing a caliper of claim 14, wherein the measured deflection of the caliper housing does not exceed 2.9 mm.
16. A method of manufacturing a caliper for a disc brake, the method comprising the acts of: forming a caliper housing of cast iron; and applying a pre-stressing load to the caliper housing, wherein the pre-stressing load is high enough to cause
iron brake caliper housing, wherein the pre-stressing load is high enough to cause localized plastic deformation in the cast iron brake caliper housing, and below a load high enough to cause failure of the cast iron brake caliper by crack initiation;17. A method for improving fatigue life of a cast iron brake caliper by pre- stressing, the method comprising the acts of: inserting a housing of the cast iron brake caliper into a pre-stressing fixture; applying a pre-stressing load to the cast
least one of applied load, load ramp-up rate, load duration, load reduction rate and cast iron brake caliper housing deflection amount.18. The cast iron brake caliper pre-stressing method of claim 17, further comprising the act of: after each of the load applying, load maintaining and load removing, determining whether a predetermined process specification is exceeded for at
a vehicle, and the pre-stressing load is increased in a controlled manner in accordance with a predetermined pre-stressing loading schedule, and during the load removing, the pre-stressing load is decreased in a controlled manner in accordance with a19. The cast iron brake caliper pre-stressing method of claim 17, wherein during the load applying, the pre-stressing load is applied to the cast iron brake caliper in the same manner as a braking load is applied to the caliper when in service on
predetermined pre-stressing unloading schedule is a linear decrease in load from the predetermined maximum pre-stressing load to an unloaded condition.20. The cast iron brake caliper pre-stressing method of claim 19, wherein the predetermined pre-stressing loading schedule is a linear increase in load from an unloaded condition to a predetermined maximum pre-stressing load, and the
rejected.21. The cast iron brake caliper pre-stressing method of claim 20, wherein if a predetermined process specification is exceeded during at least one of the load applying, load maintaining and load removing steps, the cast-iron brake caliper is
plastic deformation in the cast iron brake caliper housing, and below a load high enough to cause failure of the cast iron brake caliper by crack initiation, maintaining the pre-stressing load a predetermined period sufficient to permit the localized22. The cast iron brake caliper pre-stressing method of claim 21, wherein the load applying, load maintaining and load removing steps are performed more than one time before the cast iron brake caliper is removed from the pre-stressing fixture.
23. A disc brake component, comprising: a cast iron brake caliper housing, wherein the cast iron brake caliper housing includes at least one plastically-deformed region.
24. The disc brake component of claim 23, wherein the at least one plastically deformed region is formed by applying a pre-stressing load to the cast iron brake caliper housing, wherein the pre-stressing load is high enough to cause localized
module for transferring a pre-stressing load from a brake actuator side of the cast iron brake caliper to a reaction side of the cast iron brake caliper; at least one sensor for detecting at least one pre-stressing control parameter for feedback control25. A brake caliper pre-stressing apparatus, comprising: a fixture for receiving a cast iron brake caliper for pre-stressing; a pre-stressing force actuator adapted to apply a pre-stressing load to the cast iron brake caliper; a force transfer
loading schedule includes the steps of: applying the pre-stressing load to the cast iron brake caliper, wherein the pre-stressing load is high enough to cause localized plastic deformation in the cast iron brake caliper housing, and below a load high26. The brake caliper pre-stressing apparatus of claim 25, wherein the at least one sensor includes at least one of a caliper deflection sensor and a pre-stressing load sensor.
27. The brake caliper pre-stressing apparatus of claim 25, wherein the controller is further programmed to control application of the pre-stressing force in accordance with a pre-determined pre-stressing loading schedule, where the pre-stressing
schedule, the pre-stressing loading schedule including the acts of: applying a pre-stressing load to the cast iron brake caliper, wherein the pre-stressing load is high enough to cause localized plastic deformation in the cast iron brake caliper housing,28. A computer product comprising a computer-readable storage medium having stored therein code segments for causing a brake caliper pre-stressing apparatus to pre-stress a cast iron brake caliper in accordance with a pre- stressing loading
and cast iron brake caliper housing deflection amount; and rejecting a caliper housing if at least one predetermined process specification is exceeded.29. The computer product of claim 28, wherein code segments cause the brake caliper pre-stressing apparatus to maintain the pre-stressing load over a predetermined period sufficient to permit localized plastic deformation to occur.
30. The computer product of claim 29, wherein code segments cause the brake caliper pre-stressing apparatus to remove the pre-stressing load after the pre-determined period has expired.
31. The computer product of claim 30, wherein code segments further include the acts of: determining whether a predetermined process specification is exceeded for at least one of applied load, load ramp-up rate, load duration, load reduction rate
loading schedule, and decrease the pre-stressing load during the load removing in a controlled manner in accordance with a predetermined pre- stressing unloading schedule.32. The computer product of claim 31, wherein code segments cause the brake caliper pre-stressing apparatus to increase the pre-stressing load during the load applying in a controlled manner in accordance with a predetermined pre-stressing
schedule is a linear decrease in load from the predetermined maximum pre-stressing load to an unloaded condition.33. The computer product of claim 31, wherein code segments cause the brake caliper pre-stressing apparatus to perform the load applying more than one time to the same cast iron brake caliper.
34. The computer product of claim 32, wherein the predetermined pre-stressing loading schedule is a linear increase in load from an unloaded condition to a predetermined maximum pre-stressing load, and the predetermined pre-stressing unloading
accordance with a pre-stressing loading schedule, the pre-stressing loading schedule including the acts of: applying a pre-stressing load to the cast iron brake caliper, wherein the pre-stressing load is high enough to cause localized plastic deformation35. The computer product of claim 34, wherein the applied pre-stressing load is increased from 0 to between 120 kN and 400 kN.
36. The computer product of claim 34, wherein the applied pre-stressing load is increased from 0 to between 250 kN and 300 kN.
37. The computer product of claim 34, wherein the applied pre-stressing load is increased from 0 to approximately 255 kN.
38. A controller for controlling the operation of a brake caliper pre- stressing apparatus, the controller having stored therein code segments for causing a brake caliper pre-stressing apparatus to pre-stress a cast iron brake caliper in
plastic deformation in the cast iron brake caliper housing, and below a load high enough to cause failure of the cast iron brake caliper by crack initiation, maintaining the pre-stressing load a predetermined period sufficient to permit localized plastic39. A disk brake assembly, comprising: a brake rotor; and a cast iron brake caliper which straddles the brake rotor when in an in-use position, wherein a housing of the cast iron brake includes at least one plastically-deformed region.
40. The disk brake assembly of claim 39, wherein the at least one plastically deformed region is formed by applying a pre-stressing load to the cast iron brake caliper housing, wherein the pre-stressing load is high enough to cause localized
Approx. Webbing Volume 16 cm x 16 cm x 1 cm x two webs = 512 cm^3
4.0 * 10^10 dynes
400,000 Newtons
kilogram per cubic centimeter (kg/cm³) 0.00787
512 cm^3 * 0.00787 kg = 4.02944 kg
(400 000 newtons) * 4.02944 kilograms = 1.61 * 10^6 Joules
1 611 776 * 0.003 meter stretch = 4835.328
On Wednesday, March 23, 2016 at 6:59:29 PM UTC-5, fuller...@hotmail.com wrote:
On Wednesday, March 23, 2016 at 6:57:31 PM UTC-5, fuller...@hotmail.com wrote:
On Wednesday, March 23, 2016 at 6:46:10 PM UTC-5, fuller...@hotmail.com wrote:
On Wednesday, March 23, 2016 at 6:42:07 PM UTC-5, fuller...@hotmail.com wrote:
http://www.google.com/patents/US8423191 http://www.google.com/patents/WO2010107612A1
localized plastic deformation in the cast iron brake caliper housing, and below a load high enough to cause failure of the cast iron brake caliper by crack initiation.CLAIMS(1)
WHAT IS CLAIMED IS:
1. A method of manufacturing a caliper for a disc brake, the method comprising the acts of: forming a caliper housing of cast iron; and applying a pre-stressing load to the caliper housing, wherein the pre-stressing load is high enough to cause
result of material creep under the pre-stressing load.2. The method of manufacturing a caliper of claim 1, wherein the caliper is a multi-piece caliper.
3. The method of manufacturing a caliper of claim 1, wherein the pre- stressing load is maintained over a predetermined period sufficient to permit localized plastic deformation to occur.
4. The method of manufacturing a caliper of claim 3, wherein the pre- stressing load is maintained over a predetermined period which does not exceed a length of time associated with reaching a predetermined maximum permissible % elongation as a
at least one of applied load, load ramp-up rate, load duration, load reduction rate and cast iron brake caliper housing deflection amount; and rejecting a caliper housing if at least one predetermined process specification is exceeded.5. The method of manufacturing a caliper of claim 4, wherein the pre- stressing load is removed after the pre-determined period has expired.
6. The method of manufacturing a caliper of claim 5, further comprising the act of: placing the caliper housing into a pre-stressing fixture prior to applying the pre-stressing load.
7. The method of manufacturing a caliper of claim 5, wherein after each of load applying, load maintaining and load removing, the method further comprising the acts of: determining whether a predetermined process specification is exceeded for
and the pre-stressing load is increased in a controlled manner in accordance with a predetermined pre-stressing loading schedule, and during the load removing, the pre-stressing load is decreased in a controlled manner in accordance with a predetermined8. The method of manufacturing a caliper of claim 7, wherein during the load applying, the pre-stressing load is applied to the cast iron brake caliper in the same manner as a braking load is applied to the caliper when in service on a vehicle,
stressing unloading schedule is a linear decrease in load from the predetermined maximum pre-stressing load to an unloaded condition.9. The method of manufacturing a caliper of claim 8, wherein the load applying act is performed more than one time before the cast iron brake caliper housing is removed from the pre-stressing fixture.
10. The method of manufacturing a caliper of claim 8, wherein the predetermined pre-stressing loading schedule is a linear increase in load from an unloaded condition to a predetermined maximum pre-stressing load, and the predetermined pre-
cause stress levels in the cast iron brake caliper housing high enough to cause plastic elongation in the cast iron, and below a load high enough to cause failure of the cast iron brake caliper by exceeding an ultimate strength of the cast iron.11. The method of manufacturing a caliper of claim 10, wherein the applied pre-stressing load is increased from 0 to between 120 kN and 400 kN.
12. The method of manufacturing a caliper of claim 10, wherein the applied pre-stressing load is increased from 0 to between 250 kN and 300 kN.
13. The method of manufacturing a caliper of claim 10, wherein the applied pre-stressing load is increased from 0 to approximately 255 kN.
14. The method of manufacturing a caliper of claim 10, wherein the applied pre-stressing load is controlled in response to a measured deflection of the caliper housing.
15. The method of manufacturing a caliper of claim 14, wherein the measured deflection of the caliper housing does not exceed 2.9 mm.
16. A method of manufacturing a caliper for a disc brake, the method comprising the acts of: forming a caliper housing of cast iron; and applying a pre-stressing load to the caliper housing, wherein the pre-stressing load is high enough to
cast iron brake caliper housing, wherein the pre-stressing load is high enough to cause localized plastic deformation in the cast iron brake caliper housing, and below a load high enough to cause failure of the cast iron brake caliper by crack initiation;17. A method for improving fatigue life of a cast iron brake caliper by pre- stressing, the method comprising the acts of: inserting a housing of the cast iron brake caliper into a pre-stressing fixture; applying a pre-stressing load to the
least one of applied load, load ramp-up rate, load duration, load reduction rate and cast iron brake caliper housing deflection amount.18. The cast iron brake caliper pre-stressing method of claim 17, further comprising the act of: after each of the load applying, load maintaining and load removing, determining whether a predetermined process specification is exceeded for at
on a vehicle, and the pre-stressing load is increased in a controlled manner in accordance with a predetermined pre-stressing loading schedule, and during the load removing, the pre-stressing load is decreased in a controlled manner in accordance with a19. The cast iron brake caliper pre-stressing method of claim 17, wherein during the load applying, the pre-stressing load is applied to the cast iron brake caliper in the same manner as a braking load is applied to the caliper when in service
predetermined pre-stressing unloading schedule is a linear decrease in load from the predetermined maximum pre-stressing load to an unloaded condition.20. The cast iron brake caliper pre-stressing method of claim 19, wherein the predetermined pre-stressing loading schedule is a linear increase in load from an unloaded condition to a predetermined maximum pre-stressing load, and the
rejected.21. The cast iron brake caliper pre-stressing method of claim 20, wherein if a predetermined process specification is exceeded during at least one of the load applying, load maintaining and load removing steps, the cast-iron brake caliper is
plastic deformation in the cast iron brake caliper housing, and below a load high enough to cause failure of the cast iron brake caliper by crack initiation, maintaining the pre-stressing load a predetermined period sufficient to permit the localized22. The cast iron brake caliper pre-stressing method of claim 21, wherein the load applying, load maintaining and load removing steps are performed more than one time before the cast iron brake caliper is removed from the pre-stressing fixture.
23. A disc brake component, comprising: a cast iron brake caliper housing, wherein the cast iron brake caliper housing includes at least one plastically-deformed region.
24. The disc brake component of claim 23, wherein the at least one plastically deformed region is formed by applying a pre-stressing load to the cast iron brake caliper housing, wherein the pre-stressing load is high enough to cause localized
module for transferring a pre-stressing load from a brake actuator side of the cast iron brake caliper to a reaction side of the cast iron brake caliper; at least one sensor for detecting at least one pre-stressing control parameter for feedback control25. A brake caliper pre-stressing apparatus, comprising: a fixture for receiving a cast iron brake caliper for pre-stressing; a pre-stressing force actuator adapted to apply a pre-stressing load to the cast iron brake caliper; a force transfer
stressing loading schedule includes the steps of: applying the pre-stressing load to the cast iron brake caliper, wherein the pre-stressing load is high enough to cause localized plastic deformation in the cast iron brake caliper housing, and below a26. The brake caliper pre-stressing apparatus of claim 25, wherein the at least one sensor includes at least one of a caliper deflection sensor and a pre-stressing load sensor.
27. The brake caliper pre-stressing apparatus of claim 25, wherein the controller is further programmed to control application of the pre-stressing force in accordance with a pre-determined pre-stressing loading schedule, where the pre-
schedule, the pre-stressing loading schedule including the acts of: applying a pre-stressing load to the cast iron brake caliper, wherein the pre-stressing load is high enough to cause localized plastic deformation in the cast iron brake caliper housing,28. A computer product comprising a computer-readable storage medium having stored therein code segments for causing a brake caliper pre-stressing apparatus to pre-stress a cast iron brake caliper in accordance with a pre- stressing loading
rate and cast iron brake caliper housing deflection amount; and rejecting a caliper housing if at least one predetermined process specification is exceeded.29. The computer product of claim 28, wherein code segments cause the brake caliper pre-stressing apparatus to maintain the pre-stressing load over a predetermined period sufficient to permit localized plastic deformation to occur.
30. The computer product of claim 29, wherein code segments cause the brake caliper pre-stressing apparatus to remove the pre-stressing load after the pre-determined period has expired.
31. The computer product of claim 30, wherein code segments further include the acts of: determining whether a predetermined process specification is exceeded for at least one of applied load, load ramp-up rate, load duration, load reduction
loading schedule, and decrease the pre-stressing load during the load removing in a controlled manner in accordance with a predetermined pre- stressing unloading schedule.32. The computer product of claim 31, wherein code segments cause the brake caliper pre-stressing apparatus to increase the pre-stressing load during the load applying in a controlled manner in accordance with a predetermined pre-stressing
schedule is a linear decrease in load from the predetermined maximum pre-stressing load to an unloaded condition.33. The computer product of claim 31, wherein code segments cause the brake caliper pre-stressing apparatus to perform the load applying more than one time to the same cast iron brake caliper.
34. The computer product of claim 32, wherein the predetermined pre-stressing loading schedule is a linear increase in load from an unloaded condition to a predetermined maximum pre-stressing load, and the predetermined pre-stressing unloading
accordance with a pre-stressing loading schedule, the pre-stressing loading schedule including the acts of: applying a pre-stressing load to the cast iron brake caliper, wherein the pre-stressing load is high enough to cause localized plastic deformation35. The computer product of claim 34, wherein the applied pre-stressing load is increased from 0 to between 120 kN and 400 kN.
36. The computer product of claim 34, wherein the applied pre-stressing load is increased from 0 to between 250 kN and 300 kN.
37. The computer product of claim 34, wherein the applied pre-stressing load is increased from 0 to approximately 255 kN.
38. A controller for controlling the operation of a brake caliper pre- stressing apparatus, the controller having stored therein code segments for causing a brake caliper pre-stressing apparatus to pre-stress a cast iron brake caliper in
plastic deformation in the cast iron brake caliper housing, and below a load high enough to cause failure of the cast iron brake caliper by crack initiation, maintaining the pre-stressing load a predetermined period sufficient to permit localized plastic39. A disk brake assembly, comprising: a brake rotor; and a cast iron brake caliper which straddles the brake rotor when in an in-use position, wherein a housing of the cast iron brake includes at least one plastically-deformed region.
40. The disk brake assembly of claim 39, wherein the at least one plastically deformed region is formed by applying a pre-stressing load to the cast iron brake caliper housing, wherein the pre-stressing load is high enough to cause localized
Approx. Webbing Volume 16 cm x 16 cm x 1 cm x two webs = 512 cm^3
4.0 * 10^10 dynes
400,000 Newtons
kilogram per cubic centimeter (kg/cm³) 0.00787
512 cm^3 * 0.00787 kg = 4.02944 kg
(400 000 newtons) * 4.02944 kilograms = 1.61 * 10^6 Joules
1 611 776 * 0.003 meter stretch = 4835.328
(4 835.328 joules) * 5 seconds = 24176.64 Joules
http://patentimages.storage.googleapis.com/US8423191B2/US08423191-20130416-D00008.png
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