Sand Core Assembly for Vented Brake Rotors with Embedded Damping Inserts
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Solution Overview
Problem
Manufacturing noise-damped, vented brake rotors with embedded inserts for vibration damping and cooling vents is challenging due to the need for a practical and economical method that effectively suppresses brake squeal and integrates sound damping inserts into the casting process.
Innovation Solution
A three-part sand core assembly is used in a sand mold casting process to simultaneously cast pairs of brake rotors with embedded sound damping inserts and cooling vents, allowing for the simultaneous production of multiple rotors with integrated noise damping and ventilation features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional separate manufacturing methods are used for brake rotors, then manufacturing flexibility and simplicity are maintained, but manufacturing efficiency and cost-effectiveness deteriorate due to inability to produce multiple rotors simultaneously
Solution Approach 1:
The sand core assembly is segmented into multiple modular components including a central core, satellite cores, and connector pieces. Each segment can be independently manufactured and then assembled together to form the complete multi-rotor casting assembly, enabling simultaneous production of multiple rotors while maintaining manufacturing flexibility
Solution Approach 2:
Multiple rotor casting operations are merged into a single unified sand core assembly structure. The assembly combines several individual rotor cavities and their corresponding core components into one integrated unit that can be cast simultaneously, dramatically improving manufacturing efficiency and cost-effectiveness
2Object-affected harmful factors
If noise damping inserts are added to brake rotors, then brake squeal suppression is improved, but manufacturing complexity and process difficulty worsen
Solution Approach 1:
The noise damping inserts are pre-positioned within the sand core assembly before the casting process begins. The inserts are securely held in their final positions by the core structure, ensuring correct placement without requiring complex post-casting operations or specialized tooling
Solution Approach 2:
The sand core assembly itself serves as the positioning and securing mechanism for the noise damping inserts. The insert retention features are integrated directly into the core structure, eliminating the need for separate securing mechanisms or complex assembly procedures
3Temperature
If ventilation features are integrated into brake rotors, then cooling performance is improved, but manufacturing precision requirements worsen
Solution Approach 1:
The ventilation features are formed as integral parts of the sand core assembly structure itself. Core cavities and passages are pre-formed within the sand material, ensuring accurate geometry and proper alignment of venting features before the casting process begins
Solution Approach 2:
The sand core assembly provides locally optimized features for ventilation, with varying densities and structures in different regions to control airflow patterns. The core material properties and结构设计 are tailored to specific locations to achieve optimal cooling performance while maintaining manufacturing simplicity
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 enables efficient and economical production of brake rotors with embedded sound damping inserts, effectively reducing brake squeal by integrating noise damping and ventilation features into the casting process, enhancing the rotor's performance during vehicle braking.
Implementation Method 1
An insert for coulomb friction damping may be enclosed within either or both of the rotor body portions
Data Source
AI summary
An assembly of like two rib cores enclosing a splitter core are used to carry two or four sound damping inserts for sand mold casting of a pair of vented and damped brake rotors. Sand mold bodies are configured to define outboard surfaces of hub and rotor surfaces of the cast brake rotors. The three-piece core assembly is shaped to define the complex inner surfaces in casting of vented rotor bodies carrying one or two annular sound damping inserts.