Segmented Friction Disk Liner With Rib-Channel Torque Transfer
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Solution Overview
Problem
Current aircraft braking systems face issues with torque transfer problems and material wastage due to the use of single-piece wear liners, which can warp and require inefficient manufacturing processes.
Innovation Solution
The implementation of segmented wear liners with integrated torque ribs and channels on the friction disk core, allowing for improved torque transfer and reduced material waste by utilizing a different material for the wear liners, which can be easily replaced and manufactured without cutting down a whole disk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-piece wear liner is used, then the manufacturing process is simple, but material wastage increases as the entire disk must be formed and the center removed
Solution Approach 1:
The wear liner is divided into multiple segments that can be manufactured separately and then assembled onto the friction disk core. This allows each segment to be optimally sized and shaped, eliminating the need to remove the center portion of a complete disk and reducing material wastage while maintaining manufacturing simplicity
Solution Approach 2:
The segmented wear liner segments are designed to fit around and attach to the friction disk core, with segments nesting together to form a complete annular liner. This nested configuration allows efficient use of material by only manufacturing the necessary annular portions rather than complete disks
2Reliability
If a flange attachment method is used for wear liners, then the liner can be attached to the core, but torque transfer problems occur particularly when the liner is worn
Solution Approach 1:
The attachment features (ribs on liner segments matching channels in the core) are integrated directly into the wear liner segments and friction disk core structure, merging the attachment function with the structural components. This eliminates separate flange attachments and provides reliable torque transfer that maintains effectiveness even as the liner wears
Solution Approach 2:
The friction disk core and wear liner segments are designed as composite structures with different materials optimized for their specific functions. The core provides structural integrity with channels for attachment, while the liner segments provide friction surface with integrated ribs, creating a composite system that maintains torque transfer capability throughout the liner's service life
3Device complexity
If a single-piece wear liner is used, then the structure is simple, but warping occurs during service
Solution Approach 1:
Dividing the wear liner into multiple separate segments that are assembled onto the friction disk core eliminates the warping issue. Each segment is smaller and less prone to thermal stress-induced deformation, and the segmented configuration allows for better thermal management and reduced thermal gradients that cause warping in large single-piece liners
Data Source
AI summary
A friction disk includes a friction disk core having a first surface with multiple channels extending radially across the first surface. The friction disk may further include a first wear liner having two wear liner segments each configured to be coupled to the first surface of the friction disk core to form an annular liner and each including a wear surface, a non-wear surface, and a rib extending from the non-wear surface and configured to be received by one of the multiple channels.