Friction Disc Composite Blanking for Flexible Geometry Production
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Solution Overview
Problem
Existing methods for producing friction discs require the carrier disc to have its final form before the friction lining is glued on, limiting flexibility and increasing production time and costs, especially for smaller discs with diverse geometries.
Innovation Solution
A method where the carrier element and friction lining are connected to form a composite material before determining the geometry of the friction disc, using a cutting separation method, such as punching, to produce discs with low thickness and density tolerances, and allowing for easy adaptation to different geometries by modifying the tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the carrier disc is given its final form before the friction lining is glued on, then the processing can be completed in a standardized sequence, but the production time increases and flexibility for different geometries decreases
Solution Approach 1:
The friction lining is glued to the carrier element in its blank state before the final geometry is determined. This preliminary bonding action allows the components to be joined early in the process, eliminating the need to wait for the carrier disc to be fully formed, thus reducing production time while maintaining manufacturing simplicity
Solution Approach 2:
The process allows for dynamic adaptation to different friction disc geometries by modifying the cutting separation tool rather than the entire production sequence. This dynamic approach enables quick reconfiguration for different geometries without disrupting the established bonding process, improving both productivity and flexibility
2Manufacturing precision
If the carrier disc is punched out before gluing the friction lining, then the carrier has its final form for precise fitting, but the production process becomes more time-consuming and less flexible
Solution Approach 1:
The friction lining is bonded to the carrier element before the cutting separation step that determines the final geometry. This preliminary bonding maintains precision requirements while reordering operations to reduce cycle time, as the precision-critical cutting operation occurs after bonding is complete
Solution Approach 2:
The production process is segmented into distinct phases: bonding phase (where precision is maintained by bonding flat surfaces) and geometry determination phase (where the final shape is created through cutting separation). This segmentation allows each phase to be optimized independently, maintaining precision while improving overall productivity
3Productivity
If the friction lining and carrier element are connected before determining the geometry, then the production process is simplified and time is reduced, but the tolerances for thickness and density must be controlled
Solution Approach 1:
The bonding of friction lining to carrier element is performed as a preliminary action before geometry determination. This allows the bonding process to proceed under controlled conditions with flat surfaces, ensuring that thickness and density tolerances are maintained during the high-speed bonding operation, while the final geometry is precisely established in the subsequent cutting separation step
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 approach simplifies the production process, reduces cycle times, and lowers costs by enabling swift adjustments to disc geometries, achieving high productivity and precise tolerances, particularly beneficial for smaller friction discs.
Implementation Method 1
connecting the friction lining to the carrier element by means of an adhesive agent to form a composite material
Implementation Method 2
the geometry of the friction disc is determined by a cutting separation method
Data Source
AI summary
A method for producing a friction disc includes the steps: providing a carrier element, providing at least one friction lining; connecting the friction lining to the carrier element by an adhesive agent to form a composite material, wherein the carrier element is connected to the friction lining to form the composite material before the geometry of the friction disc is determined.