Brake Disc Corrugated Chamfering for Uniform Sagging Control
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Solution Overview
Problem
The existing methods for manufacturing brake discs with corrugated portions suffer from variations in chamfering, leading to inconsistent brake performance, increased costs due to manual chamfering, and issues with sagging and burrs during the pressing process, particularly in petal-shaped discs with concave and convex surfaces.
Innovation Solution
A method involving press molding, mold setting with a slope corresponding to the corrugated portion, and a surface press step to uniformly form chamfer portions, with adjustable clearance between molds to ensure consistent sagging and chamfering, and optional burr removal and finishing steps to enhance brake disc quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If chamfering is performed by cutting, then chamfering can be achieved, but man-hours increase causing cost increase
Solution Approach 1:
The patent replaces the cutting method (mechanical removal of material) with a press molding method (mechanical deformation). The angular portion is formed by pressing the plate-like member between molds with appropriate clearance, transforming the material through plastic deformation rather than cutting, thereby eliminating manual intervention and reducing costs while maintaining chamfering quality
Solution Approach 2:
The patent utilizes parameter changes in the press molding process, specifically adjusting the clearance between the upper and lower molds, and controlling the press force and press speed. By optimizing these parameters, the method achieves consistent chamfering angles and uniform sagging control across different regions of the brake disc, resolving the quality inconsistency issue
2Manufacturing precision
If clearance between upper mold and lower mold is increased to ensure sagging amount, then sagging is ensured, but burrs increase affecting positioning accuracy
Solution Approach 1:
The patent applies parameter changes by establishing specific clearance ranges between the upper and lower molds (0.5-2.0mm for circular discs, 1.0-3.0mm for petal-shaped discs). It also controls the press force (5-20 tons) and press speed (10-50mm/s) to achieve the desired balance between sufficient sagging and minimal burr formation, transforming qualitative requirements into quantitative control parameters
3Manufacturing precision
If press molding is performed with large clearance to ensure sagging, then sagging is sufficient, but ridge on side surface increases
Solution Approach 1:
The patent controls the clearance between molds within specific ranges and adjusts the press speed (10-50mm/s) and press force (5-20 tons) to prevent excessive material flow that causes ridges. By optimizing these parameters, the method achieves sufficient sagging while maintaining smooth side surfaces without ridge formation
Solution Approach 2:
The patent employs continuous press molding where the upper mold continuously presses the plate-like member into the lower mold throughout the forming process. This continuous action ensures uniform material flow and deformation, preventing intermittent pressing that could cause ridge formation on the side surfaces while maintaining consistent sagging
4Productivity
If chamfering is performed by pressing in conventional methods, then automation is improved, but variation in chamfering amount occurs affecting brake performance
Solution Approach 1:
The patent applies local quality by designing the mold surfaces with different characteristics for different regions. The upper mold has a pressing surface that contacts the angular portion, while the lower mold has a corresponding recess. The clearance and surface geometry are locally optimized to ensure uniform chamfering across concave and convex portions, addressing the inconsistency issue through localized mold design
Solution Approach 2:
The press molding method serves multiple functions simultaneously: it forms the corrugated shape with concave and convex portions, creates the chamfered angular edges, and controls sagging uniformity all in a single operation. This multi-functionality eliminates the need for separate chamfering operations and ensures consistent results across different regions of the brake disc
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 method achieves uniform chamfering and sagging across the brake disc's circumference, reducing brake performance variability and eliminating ridges, thereby improving the manufacturing efficiency and effectiveness of brake discs.
Implementation Method 1
a surface press step of deforming the angular portion in contact with the slope by pressing the brake-disc intermediate product set in the mold in a direction of the mold, to mold a chamfer portion
Implementation Method 2
a press step of molding, by press molding, a brake-disc intermediate product that includes a corrugated portion in which a concave portion and a convex portion are repeatedly formed over an outer circumference
Data Source
AI summary
In a brake-disc intermediate product, a corrugated portion is molded using an upper mold and a lower mold. The brake-disc intermediate product is set in a mold, the mold has a slope corresponding to the corrugated portion, and an angular portion formed along the outer circumferential edge of the corrugated portion is in contact with the slope in a state where the brake-disc intermediate product is set in the mold. The angular portion in contact with the slope is deformed by pressing the brake-disc intermediate product in a direction of the mold, to mold a chamfer portion. The slope is formed so that a chamfering angle formed with respect to an inner bottom surface of the mold is larger at a portion in contact with the concave portion than a chamfering angle at a portion in contact with the convex portion.