Co-Cast Brake Disk Structure for Torque and Thermal Stress
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Solution Overview
Problem
Existing disk brake disks composed of two separate parts, typically a cast iron braking band and a light alloy support bell, face challenges in transmitting braking torque and withstanding high thermal stresses, leading to stress peaks and conical deformation, which compromises the durability and efficiency of the coupling between the band and the bell, especially under industrial vehicle braking conditions.
Innovation Solution
A disk brake disk manufactured in a single piece by co-casting two materials, where the support bell is made of spheroidal or ductile cast iron and the braking band is made of lamellar or gray cast iron, with radially protruding bell projections and annular ribs for improved cohesion and torque transmission, eliminating the need for separate components and reducing weight and axial deflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a disk brake disk is made of two separate parts (cast iron braking band and light alloy support bell) joined by pins or welding, then the braking band can withstand high thermal stresses, but the coupling between band and bell creates stress peaks and conical deformation under high torque
Solution Approach 1:
The patent merges the braking band and support bell into a single monolithic component made entirely of cast iron through co-casting, eliminating the separate parts coupling interface that causes stress peaks and conical deformation. The single-piece construction ensures continuous material structure and uniform stress distribution throughout the disk brake assembly.
Solution Approach 2:
The patent employs composite cast iron material with specific microstructure (combining graphite flakes for braking properties with matrix strength) to achieve both thermal stress resistance and mechanical strength in a unified structure, eliminating the need for heterogeneous material joints that create stress concentration points.
2Ease of manufacture
If a disk brake disk uses two separate parts joined by adhesive bonding, then manufacturing is simple and cost-effective, but the coupling is not constant under strong thermal excursions
Solution Approach 1:
The co-casting process merges the manufacturing of braking band and support bell into a single integrated casting operation, producing a monolithic component that eliminates bonding interfaces entirely. This approach maintains manufacturing simplicity while ensuring absolute coupling consistency under all thermal conditions.
Solution Approach 2:
The patent changes the fundamental manufacturing parameter from post-casting joining (adhesive bonding) to integrated co-casting, transforming the process into a single-step operation that produces a unified structure with consistent material properties throughout, reliable under thermal excursions.
3Ease of operation
If a disk brake disk uses conventional two-part construction with geometric coupling, then assembly is straightforward, but the coupling deteriorates due to conical deformation of the bell under repeated thermal excursions
Solution Approach 1:
The patent combines the braking band and support bell into a single integrated component through co-casting, eliminating the geometric coupling interface that is susceptible to conical deformation. The monolithic construction ensures permanent geometric stability without assembly or interface deterioration under repeated thermal cycling.
4Weight of moving object
If a disk brake disk is made as a single piece by co-casting, then weight is reduced by up to 13% and axial displacement is minimized by 50%, but the manufacturing process must ensure perfect integration of two materials
Solution Approach 1:
The patent utilizes composite cast iron materials with controlled microstructure that can be co-casted in a single operation, achieving weight reduction and axial displacement minimization while ensuring perfect material integration through the inherent properties of the cast iron composite system.
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 co-casting method reduces weight by up to 13%, minimizes axial displacement by 50%, and maintains mechanical properties at elevated temperatures, ensuring a robust and efficient braking action capable of handling high torque and thermal excursions, while simplifying maintenance and setup.
Implementation Method 1
A disk brake disk manufactured in a single piece by co-casting two materials
Data Source
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AI summary
A disk brake disk or disk (1), said disk (1) being made in a single piece obtained by co-casting two materials, comprising: