Aircraft Brake Disc Density Gradient Manufacturing
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Solution Overview
Problem
Aircraft brake discs, particularly those coupled to drive keys and splines, are prone to cracking and breaking due to high torque and shock during brake system operation, as existing protection methods like metal clips are insufficient.
Innovation Solution
A method for manufacturing aircraft brake discs involves creating density gradients in rotary and fixing discs through thermal gradient chemical vapor deposition, where the density of the rotary disc increases from the center to the outside and the fixing disc decreases from the center to the outside, enhancing structural strength around critical areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal clips are attached to protect the rotary disc and fixing disc against torque and shock, then some protection is provided, but the protection is insufficient
Solution Approach 1:
The patent applies local quality by creating different density distributions in different parts of the brake disc. The rotary disc has higher density at the outer peripheral portion where the drive key couples, while the fixing disc has higher density at the inner peripheral portion where splines couple. This localized density enhancement provides targeted protection against torque and shock without requiring additional metal clips, thereby improving reliability while avoiding increased device complexity.
Solution Approach 2:
The patent changes the physical parameter of density distribution within the brake disc components. By controlling the density to vary spatially - higher at critical coupling portions for rotary discs and higher at spline portions for fixing discs - the material structure is optimized to withstand torque and shock loads more effectively, providing sufficient protection without additional protective components.
2Ease of manufacture
If uniform density is used throughout the brake disc, then manufacturing is simpler, but the critical portions coupled to drive keys and splines are more prone to cracking and breaking
Solution Approach 1:
The patent implements local quality by creating non-uniform density distributions tailored to the specific functional requirements of different disc types. Rotary discs have concentrated density at the outer peripheral portion to withstand drive key torque, while fixing discs have concentrated density at the inner peripheral portion to withstand spline loads. This localized strengthening approach maintains manufacturing feasibility while dramatically improving strength at critical portions compared to uniform density designs.
Solution Approach 2:
The patent effectively creates a composite structure within the carbon-carbon material by establishing regions of different density. The high-density regions at critical portions provide enhanced strength and crack resistance, while the overall carbon-carbon composite structure maintains the necessary thermal and friction properties. This internal composite approach achieves superior strength without complicating the manufacturing process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly increases the strength of the brake discs around the drive key and spline areas, effectively protecting them from torque and shock, thereby improving their durability and preventing premature failure.
Implementation Method 1
a second step of densifying the rotary disc preform such that density continuously increases from the center to the outside of the rotary disc and of densifying the fixing disc preform such that density continuously decreases from the center to the outside of the fixing disc
Implementation Method 2
thermal gradient chemical vapor deposition
Data Source
AI summary
A method for making an aircraft brake disc includes: a first step of manufacturing a rotary disc preform for manufacturing a rotary disc and a fixing disc preform for manufacturing a fixing disc; and a second step of densifying the rotary disc preform such that density continuously increases from the center to the outside of the rotary disc and of densifying the fixing disc preform such that density continuously decreases from the center to the outside of the fixing disc.