Brake Disc Bell and Composite Band Co-Melting
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Solution Overview
Problem
High performance brake discs for vehicles face challenges in reducing unsprung masses and optimizing the connection between the bell and braking band, leading to inefficient heat exchange and mechanical stress distribution.
Innovation Solution
A brake disc design featuring a composite braking band with a circular inner edge and polar series of hollows for co-melting with a metal bell, optimizing stress transfer and heat exchange by reducing bell volume and mass, and improving ventilation through specific hollow arrangements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the bell volume is reduced to decrease unsprung mass, then the weight of the moving object decreases, but the stress transfer area between bell and braking band is reduced
Solution Approach 1:
The coupling area is segmented into multiple hollows distributed around the braking band, creating discrete stress transfer zones that collectively provide sufficient load transfer capability while maintaining reduced bell volume
Solution Approach 2:
The hollows are strategically positioned and dimensioned to concentrate stress transfer at specific locations where needed, optimizing the local coupling quality between bell and braking band despite overall volume reduction
2Reliability
If traditional co-melting processes are used, then the bell and braking band can be integrated, but the manufacturing complexity and cost are high
Solution Approach 1:
The hollows are pre-formed in the braking band before the co-melting process, preparing the coupling interfaces in advance to facilitate a simpler and more reliable integration process
Solution Approach 2:
The hollows act as intermediary coupling elements that mediate the connection between the bell and braking band, enabling reliable stress transfer through a controlled interface that simplifies the overall 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
The solution enhances mechanical load transfer, reduces thermal stresses, and simplifies manufacturing, resulting in a more reliable, efficient, and cost-effective brake disc with improved cooling properties.
Implementation Method 1
Co-melting commonly means the positioning of a band made of a composite, carbon-ceramic, carbon or other material inside a suitable mold provided with casting spouts; a melted metal material, typically an aluminum alloy, is made to flow through the casting spouts according to predefined temperature and pressure parameters: the melted metal material hardens building a raw bell integral with the braking band
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
A brake disc comprising a metal bell and a braking band radially external with respect to the latter and made of composite material. The bell and the braking band are co-melted so as to define a joint area for stress transfer (11) between the bell and the braking band having a basically planar development. The definition of the joint area is achieved by forming hollows (9) and/or recesses arranged circumferentially on an inner ring of the braking band.