Brake Disc Friction Ring Casting for Improved Cooling Airflow
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Solution Overview
Problem
Existing brake disks face challenges in efficiently cooling the friction ring due to large gaps between the brake disk chamber and the friction ring, which lead to air flow obstruction and increased temperatures, limiting braking performance and design flexibility.
Innovation Solution
A brake disk design with a smaller gap between the brake disk chamber and the friction ring, achieved by using a circumferentially closed section of the inner diameter as a casting mold, resulting in improved cooling air flow and reduced thermal mass, along with conical connecting elements to minimize frictional forces and stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional casting method is used with a large gap between the brake disk chamber and friction ring, then the manufacturing process is simpler, but the cooling air flow is obstructed and temperatures increase
Solution Approach 1:
The casting process is segmented into two distinct phases: first casting the brake disk chamber with connecting elements, then separately positioning and casting the friction ring. This segmentation allows precise control of the gap between components while maintaining manufacturing feasibility, directly resolving the contradiction between temperature control and process complexity.
Solution Approach 2:
The connecting elements are pre-positioned in the brake disk chamber before the final friction ring casting. This preliminary action ensures correct positioning and establishes the optimal gap for cooling air flow before the friction ring is cast, achieving temperature control without excessive process complexity.
2Productivity
If the gap between brake disk chamber and friction ring is reduced, then cooling air flow improves, but manufacturing precision requirements increase
Solution Approach 1:
The friction ring itself serves as the casting mold for the brake disk chamber. By using the friction ring's inner circumferential surface as the mold surface, the gap is automatically controlled by the friction ring's dimensions and thermal contraction, eliminating the need for separate precision gap control mechanisms and achieving both cooling efficiency and manufacturing feasibility.
Solution Approach 2:
The friction ring is heated before casting to induce thermal expansion, creating a larger internal cavity. As the friction ring cools and contracts, it automatically establishes the optimal gap with the brake disk chamber. This thermal expansion principle transforms a precision control challenge into a self-regulating process that achieves both small gap for cooling and manufacturing simplicity.
3Strength
If connecting elements with larger diameter are used, then connection strength increases, but air flow obstruction and receiving area size increase
Solution Approach 1:
The connecting elements are designed with conical geometry rather than cylindrical, changing the dimensional parameters along their length. The varying diameter allows optimized strength distribution while minimizing the receiving area footprint and air flow obstruction, resolving the contradiction between connection strength and space occupation.
Solution Approach 2:
The connecting elements are positioned offset from the center axis in the axial direction, utilizing the third dimension (axial offset) to achieve optimal connection strength without increasing the radial footprint. This dimensional relocation reduces interference with cooling air flow while maintaining connection integrity.
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 design enhances cooling efficiency, reduces the brake disk's weight and thermal stress, improves braking performance, and allows for a more compact and lightweight structure with better material distribution, leading to increased strength and safety.
Implementation Method 1
several pin-shaped connecting elements (4) for connecting the brake disk chamber (2) with the friction ring (3)
Implementation Method 2
enhances cooling efficiency, reduces the brake disk's weight and thermal stress
Data Source
AI summary
A brake disk (1) has a brake disk chamber (2), a friction ring (3) having two friction ring disks (3a, 3b) and a plurality of pin-shaped connecting elements (4) for connecting the brake disk chamber (2) and the friction ring (3). A cooling duct (5) is formed between the fiction ring disks (3a, 3b). The friction ring disks (3a, 3b) have respective friction surfaces (3a1, 3b1) on their outer planar surfaces and respective cooling channel surfaces (3a2, 3b2) on their inner planar surfaces. The friction ring (3) has a plurality of receiving regions (7) for receiving the pin-shaped connecting elements (4). The brake disk chamber (2) is cast to the connecting elements (4) in a separate step by means of casting. A gap (8) existing between the brake disk chamber (2) and the friction ring (3) has such a width (A) which results from the fact that, during casting of the brake disk chamber (2), at least one section (3d) of a lateral surface (3c) of the inner diameter of the friction ring (3) which is closed in itself in the circumferential direction is used as part of a casting mold (9). An axial extension of that part of the receiving area (7) of the friction ring (3) which extends from the cooling channel surface (3a2) in the direction of the cooling channel (5) is 2-10 mm, preferably 4-7.5 mm, even more preferably 5.5 mm.