Composite Brake Disc Chamber Reshaping to Reduce Axial Run-Out
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Solution Overview
Problem
Composite brake discs often exhibit unallowable axial run-out or wobble due to manufacturing tolerances, requiring costly post-machining processes, which can be impractical for coated brake rings.
Innovation Solution
A method involving reshaping the brake disc chamber after joining with the brake ring to reduce wobble by aligning braking surfaces perpendicularly to a reference plane, using tools to introduce forces that cause plastic deformation and minimize wobble angles, potentially incorporating axial and rotational securing mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the brake ring is pressed onto the tubular section or joined together using conventional joining methods, then the composite brake disc can be manufactured, but unallowable axial run-out or wobble arises due to manufacturing tolerances
Solution Approach 1:
The brake disc chamber is reshaped before the final joining operation to pre-compensate for expected manufacturing tolerances. By adjusting the geometry of the tubular section in advance, the joining process achieves proper alignment without generating excessive axial run-out, thus resolving the contradiction between ease of manufacture and manufacturing precision.
Solution Approach 2:
The reshaping process modifies geometric parameters of the brake disc chamber, specifically adjusting the orientation and position of the tubular section relative to the base part. By changing these parameters within the allowed tolerance range, the final assembly achieves acceptable axial run-out while maintaining manufacturing feasibility.
2Manufacturing precision
If post-machining is performed to reduce axial run-out, then manufacturing precision is improved, but additional working operations and costs are incurred
Solution Approach 1:
Instead of performing corrective machining after joining, the brake disc chamber is reshaped before joining to prevent excessive axial run-out from occurring in the first place. This preliminary adjustment eliminates the need for subsequent post-machining operations, reducing both process complexity and manufacturing costs while maintaining high precision.
3Manufacturing precision
If the brake disc chamber is reshaped after joining to reduce wobble, then manufacturing precision is improved, but the manufacturing time is increased
Solution Approach 1:
The reshaping operation is performed on the brake disc chamber before the final joining operation, rather than after. This timing allows the reshaping to be more efficient and prevents the need for additional operations later, thereby reducing total manufacturing time while achieving the required wobble angle precision.
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 method efficiently reduces axial run-out and wobble in composite brake discs, allowing for accurate alignment and minimizing manufacturing steps, thereby reducing costs and enabling mass production.
Implementation Method 1
tools are introduced into the brake disc chamber, in particular into the tubular section, in order to reshape the brake disc chamber. This reshaping is carried out in order to reduce a wobble angle that exists between the at least one braking surface and the reference plane
Data Source
AI summary
A method for manufacturing a composite brake disc including a brake ring with at least one braking surface and a brake disc chamber having a tubular section and a base part that is connected to the tubular section and by way of which a reference plane is defined. The brake disc chamber and the brake ring are joined together, and a wobble angle between the at least one braking surface and the reference plane is reduced by reshaping the brake disc chamber.