Brake Disc Expansion Elements for Thermal Stress
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Solution Overview
Problem
Existing brake disks face issues with thermo-mechanical stresses due to temperature gradients, leading to dry brake rubbing and limited material selection, as they require a non-bonded connection to allow radial expansion, which complicates manufacturing and reduces shielding effectiveness.
Innovation Solution
A brake disk design featuring a chamber ring with radially arranged expansion elements that are positively or bonded to the friction ring, allowing for radial elasticity and exclusive radial shifting to compensate for thermal expansion, thereby reducing thermo-mechanical stresses and enabling a firmer connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a non-bonded connection is used to allow radial expansion of the friction ring, then thermal expansion compensation is achieved, but manufacturing complexity increases and material selection is limited
Solution Approach 1:
The connection transitions from a rigid non-bonded state to a bonded state with controlled radial elasticity. The bonding process creates a connection that maintains radial expansion capability through elastic deformation while providing axial rigidity, changing the mechanical parameters of the connection itself.
Solution Approach 2:
The connection structure combines different material properties by bonding dissimilar materials (friction ring material and chamber ring material) together. This composite connection achieves both thermal expansion compensation and manufacturing simplicity by integrating the radial elasticity function into the bonded joint itself.
2Strength
If a non-bonded connection is used to allow radial expansion, then thermal stresses are reduced, but axial shifting control becomes difficult and shielding effectiveness decreases
Solution Approach 1:
The bonding process fundamentally changes the mechanical parameters of the connection, providing both radial elasticity for stress compensation and axial rigidity for positioning control. The bonded joint's stiffness parameters are optimized to allow radial expansion while preventing unwanted axial shifting.
3Ease of manufacture
If a firm bonded connection is used, then manufacturing is simplified and material selection is freed, but radial expansion compensation becomes difficult and thermal stresses increase
Solution Approach 1:
The bonding creates a connection with specific elastic parameters that allow controlled radial deformation. The bonded joint's radial stiffness is designed to permit expansion compensation while maintaining overall structural integrity, resolving the contradiction between firm connection and thermal adaptation.
4Temperature
If connection webs are used for radial shifting, then thermal expansion is compensated, but axially parallel shifting occurs that reduces shielding effectiveness
Solution Approach 1:
The bonded connection's mechanical parameters are optimized to provide directional flexibility - allowing radial movement for thermal expansion while constraining axial movement for shielding. The connection's stiffness anisotropy is designed to permit expansion in the radial direction while preventing parasitic axial shifting.
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 effectively reduces thermo-mechanical stresses, allows for a wider selection of materials, and enhances braking performance by minimizing axial shifting and thermal energy transfer, resulting in improved braking comfort and durability.
Implementation Method 1
the friction disk has connection webs that are positively cast and without bonding in a casting process to the radially inner chamber... the carrying part is poured without bonding to the radially inner ends of the connection webs. Only then is it ensured that the connection webs can radially shift vis-à-vis the carrying part in the case of a radially expanding friction disk conditioned by heat
Implementation Method 2
expansion elements that are arranged radially on the chamber ring, preferably on the outer circumference of the chamber ring, and are connected on their ends facing away from the chamber ring to the brake disk friction ring in the radial direction in a positive and/or bonded manner
Data Source
AI summary
A brake disk has a brake disk friction ring and a brake disk chamber that includes a chamber ring and expansion elements arranged radially on the chamber ring, and connected on their ends facing away from the chamber ring to the brake disc friction ring in a non-floating, positive manner in the radial direction. The expansion elements are longer than the shortest distance between the chamber ring and the brake disc friction ring and are radially elastic so as to adapt to thermal deformation of the brake disc friction ring.