Brake Disc Mold Plugging for Smoother Ventilation Holes
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Solution Overview
Problem
The manufacturing of ventilated brake discs with fiber composite materials faces challenges such as high surface roughness of heat dissipation holes, micro-cracks leading to low yield rates, and difficulty in precise machining, which affects heat dissipation and dynamic balance, increasing production costs and time.
Innovation Solution
A tooling mold with plugging segments and slider plates is used to perform interference fit in heat dissipation holes, followed by a siliconization process to improve surface finish and reduce dynamic imbalance, using ceramic or composite materials for the plugging segments and slider plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hole machining is performed after vapor deposition densification, then the brake disc structure is formed, but the preform becomes extremely hard making drilling difficult, leading to low efficiency, high cost, and micro-crack generation
Solution Approach 1:
The patent applies preliminary action by performing hole machining on the preform before vapor deposition densification. The heat dissipation holes are drilled into the preform when it is still relatively soft and easy to machine, avoiding the extreme hardness that develops after densification. This preliminary machining approach eliminates the need for difficult post-densification drilling and prevents micro-crack generation from forcing holes into the hardened material.
2Reliability
If subsequent siliconization treatment is performed on the brake disc after hole machining but not mold plugging, then the brake disc is completed, but high surface roughness occurs on the inner walls of the heat dissipation holes
Solution Approach 1:
The patent uses mold plugging segments as an intermediary during the siliconization process. These plugging segments are inserted into the heat dissipation holes before siliconization and remain in place during the treatment. They act as a mediator that prevents direct contact between the siliconization material and the inner walls of the holes, thereby preventing high surface roughness while still allowing the siliconization to proceed and improve heat dissipation performance.
3Productivity
If micro-cracks are generated during the prior drilling process, then hole machining is completed, but silicon streaks appear on the product surface, leading to low yield rate
Solution Approach 1:
The patent performs hole machining as a preliminary action before vapor deposition and siliconization, when the preform material is still relatively soft and ductile. This timing allows holes to be drilled without generating micro-cracks that would later propagate during densification and siliconization. By completing machining before the material hardens, the process eliminates the root cause of micro-crack formation and subsequent silicon streaks, thereby improving yield rate.
4Strength
If the preform is densely packed to achieve product formation, then structural integrity is improved, but the preform becomes extremely hard making subsequent machining difficult
Solution Approach 1:
The patent applies preliminary action by reversing the conventional sequence: instead of machining after densification, it performs hole machining on the preform before vapor deposition densification. This allows the preform to maintain its structural integrity through proper packing while remaining soft enough for easy machining. The dense packing for structural integrity is achieved during the vapor deposition process itself, not before machining.
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 tooling mold enhances the inner surface finish of heat dissipation holes, reduces machining difficulty, lowers production costs, and increases yield rates by minimizing micro-cracks and ensuring uniform airflow, thus improving heat dissipation and dynamic balance.
Implementation Method 1
The plugging segments of the tooling mold are inserted into the heat dissipation holes of the brake disc to achieve interference fit
Implementation Method 2
slider plates each of which adopts a curved structure with a uniform thickness, wherein each of the slider plates matches with each chute
Data Source
AI summary
The present disclosure provides a tooling mold for brake disc manufacturing and a method for brake disc manufacturing. The tooling mold includes plugging segments, wherein a shape of each of the plugging segments is consistent with a shape of each of heat dissipation holes, and interference fit is achieved after plugging, an end portion of each of the plugging segments being fixedly connected with a chute through a connecting rod; and slider plates each of which adopts a curved structure with a uniform thickness, wherein each of the slider plates matches with each chute to realize position adjustment of the plugging segments.