Heterogeneous Brake Disc Bridge Optimization
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Solution Overview
Problem
Brake discs manufactured from heterogeneous materials, such as gray cast iron and aluminum, face cracking issues due to differences in thermal expansion coefficients, particularly under severe conditions like high temperatures, leading to reduced durability and performance.
Innovation Solution
Optimizing the number and structure of bridges in the brake disc, specifically determining the number of bridges using equations that consider maximum braking torque, safety coefficients, and material properties to improve castability and stress relief, and employing a manufacturing method that includes pre-heating and casting with a molten aluminum alloy to enhance bonding and prevent cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a brake disc is manufactured from heterogeneous materials (gray cast iron friction part and aluminum hat part) to reduce weight, then fuel efficiency is improved, but cracks are generated in the friction part due to thermal expansion coefficient differences under severe braking conditions
Solution Approach 1:
The invention changes the geometric parameters of the bridge structure (number of bridges, width, thickness, and positioning) to optimize stress distribution. By adjusting these parameters, the bridge can effectively relieve thermal stress and mechanical stress caused by the heterogeneous material combination, preventing crack formation while maintaining the weight reduction benefits.
Solution Approach 2:
The invention uses a composite structure combining gray cast iron friction part and aluminum hat part, each material selected for its specific properties. The gray cast iron provides excellent braking characteristics and heat resistance, while the aluminum hat part reduces overall weight. The bridge structure acts as an interface that manages the interaction between these two materials.
2Reliability
If the number of bridges is increased to relieve stress and prevent cracking, then reliability is improved, but manufacturing complexity and difficulty of casting increase
Solution Approach 1:
The invention optimizes the bridge parameters (number, width, thickness) to find the best balance between stress relief effectiveness and manufacturing feasibility. The patent provides specific parameter ranges that ensure adequate stress distribution while maintaining castability and avoiding excessive manufacturing complexity.
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
The optimized brake disc design and manufacturing method effectively prevent cracking at elevated temperatures, maintaining durability and improving fuel efficiency by reducing weight while ensuring reliable braking performance.
Implementation Method 1
The brake disc used in the braking system converts kinetic energy of the vehicle to heat energy and the like by using frictional force generated through friction with a friction material
Implementation Method 2
a crack may be generated in the friction part due to a difference in a thermal expansion coefficient between a friction part made of gray cast iron and a hat part made of an aluminum alloy
Data Source
AI summary
Disclosed are a brake disc manufactured from heterogeneous materials and a method of manufacturing the brake disc. In particular, the brake disc manufactured from heterogeneous materials, in which the number of bridges may be optimized to improve castability and relieve stress, thereby eliminating occurrence of a crack and the like which may be generated due to a difference in a thermal expansion coefficient between a friction part and a hat part.