Vehicle Brake Rotor Embed Casting Design

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Solution Overview

Problem

Conventional bi-metallic vehicle brake rotors require complex and costly equipment for assembly, and their multi-component design leads to shorter operational life due to differing expansion and contraction properties of materials under high temperature conditions.

Innovation Solution

A vehicle brake rotor design that integrates the hub and friction ring without fasteners, using an embed casting process where a molten material forms the hub onto the friction ring, reducing manufacturing complexity and costs, and enhancing reliability by eliminating fastener-related issues.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If fasteners are used to connect the hub and friction ring, then the brake rotor can be assembled with separate components, but the manufacturing complexity and cost increase significantly

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidassembly complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The hub and friction ring are merged into a single integrated component through embed casting, eliminating the need for separate assembly with fasteners. The friction ring is embedded directly into the hub material during the casting process, creating a unified structure that simplifies manufacturing while maintaining structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If fasteners are used to connect the hub and friction ring, then the components can be joined together, but the reliability decreases due to potential fastener contact with the friction ring

Engineering Contradiction:

Improveoperational reliabilityVSAvoidcomponent structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

By integrating the hub and friction ring into a single cast component, the invention eliminates fasteners that could potentially contact the friction ring during operation. This merger removes the source of reliability issues while maintaining the necessary structural connection between the two functional areas.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If conventional embed casting is used to join the hub and friction ring, then the manufacturing process is simplified, but the different expansion rates of aluminum and cast iron cause operational problems under high temperature

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidthermal expansion compatibility

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The friction ring is designed with a specific geometric profile including a beveled outer peripheral edge and a counterbore feature. This local geometric modification creates a mechanical interlock that accommodates differential thermal expansion between the aluminum hub and cast iron friction ring, allowing the harder friction ring material to maintain proper engagement while the softer aluminum hub expands differently under heat.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention changes the geometric parameters of the friction ring, specifically adding a beveled edge and counterbore features, to create a mechanical interface that compensates for thermal expansion differences. These parameter changes allow the joint to accommodate dimensional changes during thermal cycling without compromising reliability.

Inventive Principle:

Principle #35Parameter changes

4Strength

If the friction ring is made harder than the hub, then the friction ring provides better wear resistance, but the embed casting process becomes more difficult

Engineering Contradiction:

Improvewear resistanceVSAvoidcasting difficulty

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The friction ring is prepared in advance with specific geometric features including the beveled outer peripheral edge and counterbore formation before the embed casting process. This preliminary preparation of the friction ring geometry facilitates the subsequent casting operation by creating defined interfaces for the molten aluminum to flow into and bond with, making the embed casting process more manageable despite the hardness difference.

Inventive Principle:

Principle #10Preliminary action

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 solution simplifies manufacturing, reduces costs, and extends the lifespan of brake rotors by eliminating fastener-related failures and minimizing material expansion discrepancies.

Implementation Method 1

The friction ring is placed into a cavity corresponding of an embed casting mold. Once this is accomplished, a molten material conventional in embed casting, such as aluminum, is poured into the cavity, and covers the lugs and the flange of the friction ring. As the molten aluminum cools, the hub is formed and is integrally joined to the friction ring.

Methodology Applied

Scientific EffectEmbed casting:

Data Source

PatentUS9982732B2Vehicle brake rotor and method of making same

Publication Date: 2018.05.29 GRI ENGINEERING & DEVELOPMENT LLC

AI summary

A method of making a vehicle brake rotor is provided, including manufacturing a friction ring with an opening, an annular flange projecting axially relative to a face of the friction ring, and a plurality of spaced lugs projecting radially from the flange. A hub is manufactured with a plurality of recesses integrally upon the friction ring. Next, the hub is manufactured or machined so that outermost ends of the lugs are visible from an exterior of the hub.