Wave-Profile Brake Disc Joint for Lower Stress and Weight
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Solution Overview
Problem
Conventional brake discs are heavy, leading to increased unsprung mass, which affects driving dynamics and comfort, and they deform under high loads, causing vibrations and thermal stresses during braking.
Innovation Solution
A brake disc design featuring a friction ring and a carrier part with interlocking driver contours that form a continuous, wave-like curve, eliminating sharp edges and allowing for a secure, gap-free connection, enabling even force distribution and reduced weight by using lighter materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If brake discs are manufactured as one-piece cast iron components, then manufacturing cost is reduced, but weight increases and thermal stress resistance deteriorates
Solution Approach 1:
The brake disc is divided into two separate components: a carrier part (hub) and a friction ring. These components are joined together through a pressing process where the friction ring is pressed onto the carrier part, forming a composite structure that combines the advantages of different materials while reducing overall weight compared to solid cast iron designs.
2Ease of manufacture
If brake discs are manufactured as one-piece cast iron components, then manufacturing cost is reduced, but deformation resistance under high loads deteriorates
Solution Approach 1:
The brake disc uses a composite construction combining a carrier part made of one material and a friction ring made of another material. This composite structure allows each component to be optimized for its specific function, with the friction ring designed to withstand thermal and mechanical stresses during braking, thereby improving deformation resistance under high loads.
3Strength
If the friction ring is pressed onto the carrier part with high pressing force, then connection strength is improved, but stress peaks and damage risk increase
Solution Approach 1:
The pressing surface of the friction ring is designed with a curvature radius that is larger than the curvature radius of the corresponding pressing surface on the carrier part. This curvature mismatch creates a gradual transition zone during the pressing process, distributing the pressing force more evenly and avoiding concentrated stress peaks that could lead to damage.
4Power
If drive contours with sharp edges are used for torque transmission, then torque transmission efficiency is improved, but stress concentration and durability deteriorate
Solution Approach 1:
The drive contours on both the carrier part and friction ring are designed with curved surfaces instead of sharp edges. The pressing surfaces have specific curvature radii that create smooth transitions, eliminating stress concentration points while maintaining effective torque transmission through the interlocking drive contour geometry.
Data Source
Figure 1~3
Figure 4~5
AI summary
The invention relates to a brake disc (1) for a vehicle, which brake disc (1) comprises a friction ring (2) and a carrier part (3) which is joined into the inner opening (10) of the friction ring (2) in a manner which is oriented concentrically in relation to the rotational axis (D) of the brake disc (1), which rotational axis (D) is provided for use. Here, driver contours (11, 14) which are shaped in a corresponding manner with respect to one another and engage into one another in a positively locking manner are formed on the outer circumference of the carrier part (3) and on the inner circumference of the friction ring (2), with the result that a connection which is rotationally locked in the circumferential direction (U) is formed between the friction ring (2) and the carrier part (3). In order to further improve a brake disc (1) of this type with regard to the simplicity of the production thereof and with regard to the durability thereof, the invention proposes that, as viewed in a section through the brake disc (1) which is oriented normally with respect to the provided rotational axis (D) of the friction ring (2), the driver contours (11, 14) have a homogeneous undulating circumferential profile in the circumferential direction (U) of the inner opening (10), in which circumferential profile a protuberance (17, 18) follows a depression (16, 19) at least three times in a jump-free sequence.