Brake Disk Cam Segmented Arm Thermal Stress Reduction
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Solution Overview
Problem
Brake disks face material stresses due to temperature differentials caused by high braking energy inputs, particularly during stop braking from high speeds, which can lead to operational safety concerns and increased stress in the brake disk cam region.
Innovation Solution
The brake disk cam is designed with two arm parts extending from the face-end friction ring portion, converging at the cam bore, with webs that are moulded and parallel to the friction ring, allowing for thermal expansion and reducing stress through a configuration that ties the cam to the brake belt via two separate webs, and features increasing radii and inclined shapes to mitigate compressive-tensile stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the brake disk cam is designed as a single solid structure, then the structural strength is improved, but the stress concentration in the web region increases under thermal expansion
Solution Approach 1:
The brake disk cam is divided into two separate arm parts (first and second arm parts) that extend from the friction ring portion. Each arm part has its own web region, creating a segmented structure that allows independent thermal expansion and reduces stress concentration in each web region while maintaining overall structural strength through the cam bore connection.
2Device complexity
If the brake disk cam arms are positioned close to the friction ring portion, then the structural compactness is improved, but the stress in the foot region increases during thermal expansion
Solution Approach 1:
The arm parts are designed with the ability to move relative to each other and to the friction ring portion during thermal expansion. The webs are shaped with increasing radii towards the friction ring portion, allowing dynamic adjustment of the arm position and orientation, which reduces stress in the foot region while maintaining structural compactness.
3Ease of manufacture
If the web radius is constant, then the manufacturing simplicity is improved, but the compressive-tensile stresses increase during brake disk screening
Solution Approach 1:
The webs are designed with non-uniform radius distribution, where the radius increases towards the friction ring portion surface. This local variation in geometry optimizes the stress distribution during brake disk screening, reducing compressive-tensile stresses in critical regions while maintaining manufacturing feasibility through standard molding processes.
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 configuration enables reduced stress in the arm parts and web regions, enhancing the brake disk's suitability for high shock and thermal loads by allowing movement and distributing forces effectively, thereby improving operational safety and reducing material stress.
Implementation Method 1
a movement possibility of the arm parts of the cam upon thermal expansion of the brake disk is provided, thus bringing about a reduction of the stress increase in the arm parts as well as in the foot region
Data Source
AI summary
The invention relates to a brake disk having a face-end friction ring portion on which a brake disk cam provided with a cam bore is molded. In order to further develop the brake disk in such a manner that adequate safeties with respect to the permissible material values on brake disks for high-energy application cases are provided and material stresses in the region of the brake disk cam of the brake disk, which are caused through temperature differentials within the brake disk as a consequence of high braking energy inputs, are reduced, the brake disk cam includes two arm parts which extend spaced from each other from the face-end friction ring portion in the direction of the cam bore and converge in front of the cam bore.