Centrifugal Casting Mold for Brake Discs with Removable Parts
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Solution Overview
Problem
The production of brake discs using lost molds is complex, expensive, and results in brake discs with poor dimensional accuracy and surface quality, requiring extensive rework and slow heat dissipation, leading to high production costs and inefficient processes.
Innovation Solution
A centrifugal casting mold device with a metal mold shell and removable mold parts that can be rotated, featuring a sprue drum space and annular mold cavities for forming brake disc components, allowing for high surface quality production, quick heat dissipation, and adjustable cooling, with the option for reusing the mold shell to reduce costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lost sand molds are used for brake disc production, then the mold can be easily manufactured, but the surface quality and dimensional accuracy of the brake disc are poor
Solution Approach 1:
The patent employs disposable sand molds that are inexpensive to manufacture and can be easily discarded after a single use. The mold cavity is formed by compacting sand around a pattern, creating a simple yet effective single-use mold system that prioritizes ease of manufacture over reusability.
Solution Approach 2:
Instead of creating a precise reusable mold that requires complex manufacturing, the patent inverts the approach by using an imprecise disposable sand mold that is easily manufactured. The precision is achieved not through the mold itself but through the casting process and subsequent minimal rework of the brake disc.
2Device complexity
If lost sand molds are used, then the mold structure is simple, but extensive rework is required after casting
Solution Approach 1:
The sand mold is designed as a disposable component with simple structure that is discarded after one use. This eliminates the need for complex reusable mold structures while accepting that the cast part requires subsequent rework operations.
Solution Approach 2:
The manufacturing process is segmented into distinct stages: simple mold preparation, casting, and post-casting rework. This segmentation allows each stage to be optimized independently, with the mold stage focusing on simplicity and the rework stage handling precision requirements.
3Quantity of substance
If sand molds are used, then the mold material is easy to obtain, but heat dissipation is slow and the casting process takes long time
Solution Approach 1:
The sand mold uses readily available sand material that is easy to obtain and process. Although sand has poor thermal conductivity and slow heat dissipation, this is accepted as a trade-off for the ease of material acquisition and simple mold preparation process.
4Device complexity
If lost sand molds are used, then the initial production setup is simple, but production costs are high due to material recycling requirements
Solution Approach 1:
The sand mold is designed as a disposable component that is inexpensive to manufacture from common materials like sand and binders. The low cost of individual molds offsets the need for complex recycling infrastructure, making the overall system simpler and potentially more cost-effective for certain production volumes.
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 solution enables the production of brake discs with high dimensional accuracy and surface quality, reducing rework requirements, lowering production costs, and allowing for efficient cooling, resulting in faster production with minimal recycling of cycle materials.
Implementation Method 1
centrifugal molds made of metal as such quickly dissipate heat
Implementation Method 2
air pockets are prevented by spinning
Data Source
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AI summary
The invention relates to a centrifugal casting mold device (1) for the production of brake discs (100a, 100b), comprising a mold shell (10) made of metal which is rotatable about an axis of rotation (A) and at least two mold forming parts (30a, 30b, 30c) which are inserted into and removed from the mold shell (10). A cavity (50) remains in the mold shell (10), which has a sprue drum chamber (51) extending along the axis of rotation (A) and connected to a sprue opening (11), and which has at least one annular mold cavity (52a, 52b, 52c) for forming a friction ring (101a, 101b) of a brake disc (100a, 100b) and/or a carrier cup (102a, 102b) of a brake disc (100a, 100b). The annular mold cavity (52a, 52b, 52c) radially surrounds the axis of rotation (A) and is connected to the sprue drum chamber (51).Furthermore, the invention relates to the use of the centrifugal casting die device in a centrifugal casting process for the manufacture of brake discs.