Brake Disk Tab Axial Securing via Slide Tool Deformation
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Solution Overview
Problem
Existing brake disk designs face issues with springback and partial tearing of tabs during bending, leading to a gap between the friction ring and the pot, affecting the durability and axial securing of the brake disc.
Innovation Solution
A method involving a slide tool with a double chamfered extension section is used to deform the tab radially and axially, ensuring a form-fitting connection between the tab and the ring tooth, eliminating gaps and enhancing axial securing without requiring additional features on the pot or friction ring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tabs are bent against the friction ring for axial securing, then axial securing is achieved, but springback causes gaps between tabs and friction ring
Solution Approach 1:
The tab is pre-formed with an extended end section that protrudes beyond the pot wall in the radial direction. This preliminary configuration allows the tab to be subsequently deformed axially into the recess of the ring tooth without requiring bending, thereby avoiding springback and gap formation while achieving reliable axial securing.
Solution Approach 2:
Instead of deforming the tab in the radial direction (bending), the invention transitions to deforming it in the axial direction. The extended end section is pressed axially into the recess of the ring tooth, changing the dimension of deformation from radial to axial, which eliminates springback issues and ensures precise form-fitting connection.
2Reliability
If tabs are bent for axial securing, then connection is achieved, but partial tearing occurs during bending
Solution Approach 1:
The tab is pre-formed with an extended end section that protrudes beyond the pot wall. This preliminary configuration eliminates the need for bending during assembly, thereby preventing partial tearing while ensuring durable connection through axial deformation into the recess of the ring tooth.
Solution Approach 2:
Instead of bending the tab radially to achieve connection, the invention inverts the approach by extending the tab radially in advance and then deforming it axially. This inversion of the deformation sequence prevents material tearing while achieving the same connection purpose.
3Reliability
If additional measures are taken for axial securing, then securing reliability improves, but device complexity increases
Solution Approach 1:
The extended end section of the tab serves multiple functions: it provides the necessary leverage for axial deformation, ensures form-fitting connection into the recess of the ring tooth, and eliminates the need for additional securing features. This multi-functionality achieves reliable axial securing without increasing device complexity.
Solution Approach 2:
The invention merges the tab structure with the securing function by integrating the extended end section directly into the tab. This combination eliminates the need for separate securing elements or additional features on the pot or friction ring, achieving reliable axial securing while maintaining simple device structure.
4Reliability
If form-fitting connection is achieved, then axial securing improves, but radial space requirements increase
Solution Approach 1:
The tab is pre-formed with an extended end section that protrudes radially. While this initial configuration requires some radial space, the subsequent axial deformation into the recess of the ring tooth minimizes the final radial dimension, achieving form-fitting connection with compact radial profile.
Solution Approach 2:
The invention moves the securing action from the radial dimension to the axial dimension. By deforming the tab axially into the recess of the ring tooth rather than bending it radially, the form-fitting connection is achieved with minimal radial space requirements, maintaining compact brake disk design.
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 method achieves a robust axial securing of the brake disc, reducing space requirements and enabling simplified cooling, as the connection is gap-free and form-fitting, thereby improving the durability and efficiency of the brake disc.
Implementation Method 1
Problems can arise when bending over the tabs, since there is always a certain amount of springback.
Implementation Method 2
the tab is pressed in the radial direction against the associated ring tooth by means of the slide tool according to the invention. Due to the double chamfering of the end face of the extension section of the slider tool according to the invention with a first and a second chamfering angle, by caulking the tab in the radial direction by means of the slider tool, the tab is simultaneously also positively pressed in the axial direction into a recess of the ring tooth and thus also deformed in the axial direction
Data Source
AI summary
The invention relates to a brake disk of a motor vehicle, comprising a pot or a wheel flange having a bottom and a surrounding wall projecting therefrom, and comprising a friction ring (2) provided with an opening (14), in which the wall is arranged. The pot and the friction ring (2) are arranged concentrically. The wall is provided with an axial pot toothing that extends along an outer circumference, having pot teeth that project radially outward. In a circumferential direction, a pot tooth gap is arranged between adjacent pot teeth, respectively. The friction ring (2) is provided with an axial ring toothing (16) that extends along an inner circumference (15), which is configured to be complementary to the pot toothing and is provided with ring teeth (17) that project radially inward. In a circumferential direction, a ring tooth gap (18) is arranged between adjacent ring teeth (17), respectively. The pot teeth engage in the ring tooth gaps (18), and the ring teeth (17) engage in the pot tooth gaps. On at least one first pot tooth gap, a tab is formed, which projects radially outward, and which radially overlaps the respective ring tooth (17) that engages in said first pot tooth gap at a first axial end (23), wherein, by means of a slider tool, the tab of the first pot tooth gap is pressed against the associated ring tooth (17) in a radial direction by way of caulking, and is deformed.