Co-Cast Brake Disk Coupling for Thermal Torque Stability
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Solution Overview
Problem
Existing disk brake disk solutions fail to achieve a durable and constant coupling between the braking band and the bell, especially under high thermal excursions and heavy braking torques, leading to inefficient torque transmission and potential mechanical failures.
Innovation Solution
A disk brake disk made in a single piece by co-casting two materials, where the bell is made of spheroidal or ductile cast iron and the braking band is made of lamellar or gray cast iron, with the bell projections and ribs providing a secure and durable coupling mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the braking band and bell are joined by stainless steel pins, then the coupling allows radial dilation of the band, but the reduced section of the pins causes apparent stress peaks during torque transmission
Solution Approach 1:
The invention merges the braking band and bell into a single-piece structure through co-casting, eliminating the need for separate joining components like pins. This integration removes stress concentration points while maintaining the structural integrity and radial dilation capability through the monolithic design.
2Ease of manufacture
If the braking band and bell are cast to adhere together, then the manufacturing process is cheap and easy, but the coupling is not constant under strong thermal excursions
Solution Approach 1:
The invention employs composite materials with different thermal expansion coefficients - the bell made of spheroidal or ductile cast iron and the braking band made of gray or lamellar cast iron. This material combination ensures constant coupling under thermal excursions while maintaining manufacturing simplicity through co-casting processes.
3Reliability
If light alloy is used for the support bell, then the probability of cracks or breakages is reduced, but the material is unsuitable for huge stresses in industrial vehicle braking
Solution Approach 1:
The invention applies local quality by using spheroidal or ductile cast iron specifically for the bell portion where high strength and stress resistance are required, while the braking band uses gray or lamellar cast iron optimized for friction and heat dissipation. This localized material selection satisfies both crack resistance and stress bearing requirements.
4Reliability
If the bell is made of spheroidal or ductile cast iron and the braking band is made of lamellar or gray cast iron through co-casting, then a durable coupling is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The invention incorporates preliminary action by designing specific geometric features (protrusions, recesses, ribs) into the co-casting process that pre-establish the durable coupling between bell and braking band. These features are integrated into the mold design, allowing the complex coupling to be achieved during a single casting operation without post-manufacturing assembly steps.
Data Source
AI summary
A disk brake disk has a bell made of a first material and a braking band made of a second material. The bell has a bell body having a radially outer bell body portion and forms a plurality of bell projections radially protruding from the radially outer bell body portion. Each bell projection has a projection base close to the radially outer bell body portion and a distal projection portion far from the radially outer bell body portion. A braking band body is coupled to the distal projection portion. Adjacent projection bases are joined to one another by a bell rib made in a single piece with the bell body and having an inner axial rib face and an outer axial rib face. The braking band body is coupled to the inner axial rib face, leaving the outer axial rib face free and externally facing the disk brake disk.