Monoblock Railway Brake Disc Bell-Shaped Flange
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Solution Overview
Problem
Conventional railway vehicle brake discs experience a reduction in press fit on the axle due to the radial expansion of the friction ring during braking, leading to potential spinning issues, as the tension in the connecting spokes compromises the hub's fit.
Innovation Solution
A monoblock brake disc design featuring a cylindrical hub, a friction ring with opposed annular members connected by pin fins, and a bell-shaped flange integrally formed from a single material, where the flange is loaded in bending rather than tension, maintaining the press fit during thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional brake discs use spokes to connect the hub to the friction ring, then the friction ring can be attached to the hub, but the tension in the spokes during thermal expansion pulls the hub away from the axle, reducing press fit and causing spinning
Solution Approach 1:
The brake disc is divided into three separate components: a hub, a friction ring, and a bell-shaped flange. The flange acts as an intermediary element that connects the hub to the friction ring, allowing each component to be optimized for its specific function while managing thermal expansion forces independently.
Solution Approach 2:
The bell-shaped flange serves as an intermediary element between the hub and friction ring. It absorbs and manages the thermal expansion forces through its geometric design, preventing these forces from being transmitted directly to the hub-axle connection, thereby maintaining press fit stability.
2Temperature
If the friction ring is allowed to expand radially outward during braking, then thermal expansion is accommodated, but the connecting spokes are stretched in tension, pulling the hub away from the axle
Solution Approach 1:
The bell-shaped flange's geometric parameters (thickness, curvature, radial extent) are specifically designed to change its mechanical behavior under thermal loading. The varying thickness and curved geometry allow the flange to flex and absorb expansion forces without generating excessive tension, accommodating thermal expansion while minimizing force transmission to the hub.
3Adaptability or versatility
If a two-piece casting with different materials is used for the friction ring and hub/flange, then material optimization is achieved, but manufacturing complexity increases
Solution Approach 1:
The hub, bell-shaped flange, and friction ring are combined into a single monoblock structure formed from one piece of metal through investment casting. This integration eliminates the need for separate materials and assembly operations, simplifying manufacturing while maintaining design flexibility through the sophisticated monoblock geometry.
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 design effectively handles higher thermal loading while maintaining the press fit between the hub and axle, preventing the brake disc from spinning and enhancing operational reliability.
Implementation Method 1
a plurality of radially-spaced pin fins extending from the inner surface of one annular member to the inner surface of the other annular member to connect the annular members to each other
Implementation Method 2
Heat generated during braking causes the friction ring to expand radially outward
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The railway vehicle brake disc includes a cylindrical hub, friction ring, and bell-shaped flange connecting the hub with the friction ring. The cylindrical hub defines a central axis and has an axial width and an outer diameter. The surface at the outer diameter defines an outer hub periphery. The friction ring includes two opposed annular members each having an outer braking surface and an inner surface. The annular members are connected to each other by a plurality of fins extending from the inner surface of one annular member to the inner surface of the other annular member. The bell-shaped flange has an inner portion connected to the hub, an outer portion connected to the fins, and a radial portion connecting the inner portion to the outer portion. The hub, friction ring, and bell-shaped flange are formed integrally from a single material.