Composite Brake Disc Hub Forming for Precise Torque Transmission
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Solution Overview
Problem
Current methods for manufacturing composite brake discs are inefficient, requiring multiple process steps and resulting in suboptimal axial run-out, rotational attachment, and torque transmission between the brake ring and brake disc hub, with limited control over play and prestress.
Innovation Solution
A method involving cold forming and embossing to create a composite brake disc by molding the brake disc hub into the inner profile of the brake ring, using an embossing tool to form a gear-like inner profile with multiple tooth roots and tips, allowing for precise alignment and torque transmission while eliminating the need for separate profiling steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple separate process steps (cold forming, profiling, punching, bending) are used to manufacture composite brake discs, then the manufacturing precision and control over alignment can be improved, but the device complexity and manufacturing time increase
Solution Approach 1:
The patent combines multiple separate manufacturing operations (cold forming, profiling, punching, and bending) into a single integrated embossing process. The embossing tool simultaneously creates the gear-like inner profile with tooth roots and tips, punches alignment features, and bends tabs during one operation, eliminating the need for multiple separate process steps while maintaining manufacturing precision
Solution Approach 2:
The embossing tool is designed as a multi-functional device that performs multiple operations: it forms the gear-like profile, creates radial indentations for rotational attachment, punches tabs for axial alignment, and bends these tabs into position. This single tool replaces several specialized tools and process steps, reducing device complexity while maintaining control over axial run-out and alignment
2Productivity
If cold forming and embossing are used to create the gear-like inner profile, then the manufacturing efficiency increases and post-processing steps are eliminated, but the control over play and prestress between components becomes limited
Solution Approach 1:
The embossing process allows control over the geometric parameters of the formed features, including the depth and shape of radial indentations, the profile of tooth roots and tips, and the dimensions of punched and bent tabs. By adjusting these embossing parameters, the patent controls the interference fit, rotational play, and axial positioning between the brake disc hub and ring, providing adaptability despite the integrated process
3Strength
If separate profiling steps are used to create toothed profiles, then the torque transmission can be optimized, but the manufacturing complexity and time increase
Solution Approach 1:
The embossing process simultaneously creates the gear-like inner profile with tooth roots and tips that are essential for torque transmission, rather than requiring a separate profiling step. The radial indentations are also formed during the same operation, ensuring proper engagement between the brake disc hub and ring for optimal torque transmission while reducing manufacturing time
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 improved axial run-out, rotational alignment, and torque transmission with selectable play and prestress, reducing manufacturing complexity and eliminating the need for post-processing steps like regrinding, resulting in a more efficient and precise composite brake disc production.
Implementation Method 1
A method involving cold forming and embossing to create a composite brake disc by molding the brake disc hub into the inner profile of the brake ring
Implementation Method 2
The brake disc hub blank inserted into the brake ring is formed into the internal profile, in particular into a gear-like internal profile with multiple tooth roots and tips
Data Source
Figure 1~2
Figure 3~4
Figure 5~6B
AI summary
The invention relates to a method for producing a composite brake disc, which has a brake disc hub and a brake ring (3) having inner profiling (2), wherein a brake disc hub blank (1a) is introduced into the brake ring (3). Then at least one stamping tool (7) is used to mold the brake disc hub blank (1a) into the inner profiling (2). In this manner, a composite brake disc, which allows good torque transmission between the brake ring (3) and the brake disc hub, can be created in a cold-formed manner. The molding can take place in a hammering manner, in particular by carrying out a plurality of stamping steps one behind the other in the region of different profiled gaps in the inner profiling (2). Axial limits can also be produced at the same time during the molding, by means of which limits the brake disc hub and the brake ring (3) are prevented from being axially pushed apart.