WO2000032330A1 - Procede de fabrication de disques de frein - Google Patents

Procede de fabrication de disques de frein Download PDF

Info

Publication number
WO2000032330A1
WO2000032330A1 PCT/US1999/027802 US9927802W WO0032330A1 WO 2000032330 A1 WO2000032330 A1 WO 2000032330A1 US 9927802 W US9927802 W US 9927802W WO 0032330 A1 WO0032330 A1 WO 0032330A1
Authority
WO
WIPO (PCT)
Prior art keywords
mold
fin core
brake rotor
sand
cooling fins
Prior art date
Application number
PCT/US1999/027802
Other languages
English (en)
Inventor
Gregory V. Miskinis
Scott Reierson
Original Assignee
Waupaca Foundry, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Waupaca Foundry, Inc. filed Critical Waupaca Foundry, Inc.
Priority to AU23470/00A priority Critical patent/AU2347000A/en
Priority to MXPA01005401A priority patent/MXPA01005401A/es
Priority to JP2000585009A priority patent/JP2002531266A/ja
Priority to EP99967125A priority patent/EP1140388A4/fr
Priority to CA002352238A priority patent/CA2352238A1/fr
Publication of WO2000032330A1 publication Critical patent/WO2000032330A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2250/00—Manufacturing; Assembly
    • F16D2250/0007—Casting

Definitions

  • the present invention relates to an improved disc brake rotor and, more particularly, to a method of casting a disc brake rotor using a fin core being made of a resin-coated silica sand and carbon sand mixture.
  • Disc rotors are commonly used in vehicle braking systems to provide improved braking performance relative to drum-type brakes.
  • Conventional disc brake assemblies include a disc rotor rotating together with a wheel of the vehicle and a pair of brake pads disposed on opposing sides of the disc rotor. The brake pads typically engage opposing brake pad contact surfaces of the disc rotor to provide factional resistance.
  • Disc brake assemblies further include a mounting member fixed to a stationary portion of the vehicle to support the brake pads. A caliper member is also provided for forcing the brake pads against the brake pad contact surfaces to decelerate the vehicle.
  • disc rotors are formed by casting using a "green” sand mold and/or a "rigid” mold.
  • Green sand molds used in horizontally casting products generally include a top half, or cope, and a bottom half, or drag.
  • green sand molds used in vertically casting products generally include a ram half and a swing half.
  • the halves are typically filled with a clay, sand, and water mixture and are rammed together around a desired pattern to form an internal cavity corresponding to the desired shape.
  • the clay /sand/water mixture is a pliable composition that will readily hold its molded shape. Molten metal may then be poured into the mold cavity to form the outer shape of the desired casting.
  • Rigid molds are generally comprised of a sand mixture, such as silica sand, that can be molded against a pattern and then hardened into a rigid state. These molds are typically hardened using various types of binders, such as clay or organic resins, and subsequently cured using various baking processes, chemical reactions, or reactive gases. Generally, organic resins produce molds that are stronger and harder than those bonded with clay.
  • a sand mixture such as silica sand
  • Cores are commonly placed or inserted into the mold during the casting process to form interior portions in the cast part. These interior portions, such as the space between brake rotor cooling fins, are formed using cores; these interior portions can not be formed using the mold, due to limitations in the casting process.
  • the cores are usually rigid members that have been shaped using the same methods and materials as those described above for rigid molds. During the casting process, the mold and cores are exposed to the extreme temperature of molten metal. The extreme temperature of the molten metal causes the sand mixture, namely the silica sand used in the mold and cores, to thermally expand and/or contract. These dimensional variations in the mold and cores are disadvantageous in that they may produce thermal distortions, such as warpage; cracks; metal penetration; and/or other defects in the mold and cores.
  • these dimensional variations in the mold and cores lead to dimensional variations in the cast brake rotor.
  • the width of the cooling fins which extend between the opposing brake plates of the cast brake rotor commonly, may vary more than 1mm.
  • the width of the cooling fins, and thus the distance between opposing brake plates, is not readily machinable. Therefore, the heat conductivity of the rotor may become uneven resulting in thermal instability of the brake rotor as a result of these dimensional variations.
  • these dimensional variations further may also effect the rotational balance of the brake rotor and may require additional machining of the outer surfaces to properly balanced the brake rotor.
  • silica sand continues to be extensively used in the casting of brake rotors because it is relatively inexpensive and readily available.
  • a method for casting brake rotors using a fin core having an advantageous composition of silica sand and carbon sand is provided.
  • an apparatus for casting dimensionally predictable brake rotors is provided.
  • the apparatus includes a first mold portion, typically a cope or ram half, and a second mold portion, typically a drag or swing half, movable relative to each other.
  • the cope and drag portions might also be ram and swing portions as used in vertical mold applications.
  • the first mold portion and the second mold portion define a mold cavity for casting the brake rotor.
  • a fin core is then provided and positioned in the mold cavity for forming a plurality of cooling fins on the brake rotor.
  • the fin core is made of a silica sand and carbon sand mixture, wherein the carbon sand is a crushed calcined petroleum coke.
  • a method for casting dimensionally predictable brake rotors including providing a cope portion and a drag portion movable relative to each other. The cope portion and drag portion define a mold cavity corresponding to a first brake surface and a second brake surface of the brake rotor. The method further includes providing a fin core for forming a plurality of cooling fins on the brake rotor.
  • the fin core is made of a silica sand and carbon sand mixture.
  • the fin core is then inserted within the mold cavity.
  • the drag portion and the cope portion are then moved together, thereby enclosing the mold cavity and the fin core.
  • a brake rotor forming material such as gray iron, is then supplied into the mold cavity, thereby flowing through the fin core.
  • the brake rotor forming material is then solidified and the improved brake rotor is removed.
  • FIG. 1 is a front view of a brake rotor forming apparatus
  • FIG. 2A is a cross-sectional view of FIG. 1, taken along line 2-2, showing the brake rotor forming apparatus having a cope half, drag half, and a fin core according to the present invention
  • FIG. 2B is a cross-sectional view of FIG. 1, taken along line 2-2, showing the brake rotor forming apparatus having a swing face, a ram face, and a fin core according to the present invention
  • FIG. 3 is a perspective view of the fin core according to the present invention.
  • the forming apparatus 10 includes a first mold portion or cope 12 having a mold cavity 14 disposed therein.
  • a second mold portion or drag 16 is provided for mating with first mold portion 12.
  • Second mold portion 16 includes a generally flat surface 18 for enclosing and defining mold cavity 14. First mold portion 12 and second mold portion 16 together form a
  • Forming apparatus 10 further includes a fin core 20 positioned in mold cavity 14, thereby defining a brake rotor cavity 22 for casting a brake rotor 24.
  • forming apparatus 10 may be a vertical molding apparatus having a plurality of mold cavities 14a, 14b, and 14c.
  • Each of the plurality of mold cavities 14a-c is defined by a swing face 23 and a ram face 25.
  • Swing face 23 is a generally flat surface extending the length of the mold.
  • Ram face 25 is a generally contoured surface extending the length of the mold. It should be appreciated that the plurality of mold cavities 14a-c enables multiple brake rotors to be formed simultaneously.
  • Each mold cavity is generally circular or disc shaped and includes a first side wall 26, a second side wall 28, an outer wall 30, and an inner wall 32.
  • First sidewall 26, outer wall 30, and inner wall 32 of mold cavity 14 are formed in first mold portion 12.
  • Second sidewall 28 of mold cavity 14 is formed in generally flat surface 18 of second mold portion 16.
  • outer wall 30 is tapered outwardly and inner wall 32 is tapered inwardly to aid in the insertion of fin core 20, as will be described below.
  • First side wall 26 and second side wall 28 respectively define a first brake pad contact surface 34 for a brake plate 35 and a second brake pad contact surface 36 for a brake plate 37 of brake rotor 24.
  • First 34 and second 36 brake pad contact surfaces are adapted to provide a braking surface for a pair of brake pads (not shown).
  • Mutually facing inner surfaces of plates 35 and 37 are separated by an interior distance A. It should be appreciated that by minimizing the dimensional variation of distance A, improved heat conductivity and corresponding heat dissipation of the finished brake rotor
  • fin core 20 is generally circular or discshaped and includes an inner or hub portion 38, an intermediate or spoke portion 40, and an outer or flange portion 42.
  • Hub portion 38 is generally ring-shaped and includes an inner tapered surface 44 adapted to closely conform to tapered inner wall 32 of mold cavity 14.
  • flange portion 42 is generally ring-shaped and includes an outer tapered surface 46 adapted to closely conform to tapered outer wall 30 of mold cavity 14.
  • Inner tapered surface 44 and outer tapered surface 46 of fin core 20 serve as draft angles to enable fin core 20 to be easily and conveniently inserted into first mold portion 12 before casting.
  • Spoke portion 40 is generally discshaped and interconnects hub portion 38 and flange portion 42.
  • Spoke portion 40 further includes a plurality of generally radially extending slots 48 for forming a plurality of cooling fins 50 in brake rotor 24.
  • each of the plurality of generally radially extending slots 48 is arcuately shaped. It is believed that this arcuate shape produces a brake rotor having cooling fins that are more capable of dissipating heat during operation.
  • any shape of slot which is conducive to various operating conditions, may be used.
  • fin core 20 is a "rigid" type core made of a silica sand and carbon sand mixture.
  • the foundry sand mixture of the present invention is in the range of about ten percent (10%) by weight carbon sand and ninety percent (90%) by weight silica sand to about one hundred percent (100%) by weight carbon sand and zero percent (0%) by weight silica sand, wherein the carbon sand is preferably crush calcined petroleum coke.
  • a mixture of about twenty- five percent (25%) by weight carbon sand and seventy-five percent (75%) by weight silica sand is presently preferred since this concentration still provides good thermal stability of the core while minimizing material costs.
  • a foundry sand mixture having 10-100% by weight carbon sand and 90%-0% by weight silica sand, respectively, for the core is within the scope of the present invention.
  • additional materials for example, but not limited to, binders, might be added to the mixture used for forming the core. However, the weight of these additional materials is believed to be negligible relative to the carbon sand and silica sand.
  • brake rotors that are cast using pure silica sand fin cores typically have a distance "A" between interior cooling surfaces of the brake plates (i.e. cooling fin width) that varies more than 1mm.
  • the brake rotors cast using the silica sand and carbon sand mixture of the present invention to form the fin cores have a cooling fin width variance of less than 1mm. Due to this minimal dimensional variation, the brake rotors have improved heat conductivity and resistance to "ripple” since the brake rotors are capable of quickly and evenly dissipating heat produced during braking. Ripple typically occurs when brake rotors are not able to dissipate heat generated during braking, such that the heat causes the rotor to distort or ripple.
  • fin core 20 is formed by first adding silica sand to a mullor or mixer for mixing. A resin and catalyst is then combined in the mixer with the silica sand in order to bind the composition together. The mixer folds the mixture for approximately three (3) minutes to thoroughly coat the silica sand with the resin and catalyst. A predetermined amount of carbon sand, preferably 1/3 the amount of silica sand used, is then added and the silica sand and carbon sand mixture is folded for approximately two (2) minutes. This specific amount of carbon sand and silica sand produces a mixture of 25 % by weight carbon sand and 75 % by weight silica sand.
  • the percentage of carbon sand and silica sand may be within the range of about ten percent (10%) by weight carbon sand and ninety percent (90%) by weight silica sand to about one hundred percent (100%) by weight carbon sand and zero percent (0%) by weight silica sand to provide the aforementioned advantages.
  • the silica sand and carbon sand mixture may then be added to an intermediate hopper and injected into a heated core forming mold. The fin core is cured for approximately 45 seconds and ejected from the mold to cure completely.
  • first mold portion 12 and second mold portion 16 are opened to enable access to mold cavity 14.
  • Fin core 20 is then inserted into mold cavity 14 such that inner tapered surface 44 and outer tapered surface 46 of fin core 20 closely conform to inner tapered wall 32 and outer tapered wall 30 of mold cavity 14, respectively.
  • First mold portion 12 and second mold portion 16 are moved together to enclose mold cavity 14 and fin core 20.
  • Molten metal such as gray iron, is then supplied into brake rotor cavity 22 under gravity through at least one injection port (not shown). The molten metal is then allowed to cool and solidify to provide a dimensionally predictable brake rotor, which is then ejected.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Braking Arrangements (AREA)
  • Mold Materials And Core Materials (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Abstract

Cette invention se rapporte à un appareil et à un procédé servant à couler des disques de frein aux dimensions prévisibles. Cet appareil comprend une première partie de moule (12) ou demi-moule du type chape/piston, et une seconde partie de moule (16) ou demi-moule de type fond/carrousel, mobiles l'une par rapport à l'autre. La première partie de moule (12) et la seconde partie de moule (16) forment une cavité de moule (14) dans laquelle est coulé le disque de frein (24). Un noyau à ailettes (20) est ensuite placé dans la cavité de moule (14) de façon à former plusieurs ailettes de refroidissement sur le disque de frein (24). Le noyau à ailettes (20) est fait d'un mélange de sable de silice et de sable de carbone, le sable de carbone étant constitué par du coke de pétrole calciné broyé.
PCT/US1999/027802 1998-11-30 1999-11-23 Procede de fabrication de disques de frein WO2000032330A1 (fr)

Priority Applications (5)

Application Number Priority Date Filing Date Title
AU23470/00A AU2347000A (en) 1998-11-30 1999-11-23 Process of making brake rotors
MXPA01005401A MXPA01005401A (es) 1998-11-30 1999-11-23 Proceso para la elaboracion de rotores de frenaje.
JP2000585009A JP2002531266A (ja) 1998-11-30 1999-11-23 ブレーキ・ロータを製造する方法
EP99967125A EP1140388A4 (fr) 1998-11-30 1999-11-23 Procede de fabrication de disques de frein
CA002352238A CA2352238A1 (fr) 1998-11-30 1999-11-23 Procede de fabrication de disques de frein

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US20150798A 1998-11-30 1998-11-30
US09/201,507 1998-11-30

Publications (1)

Publication Number Publication Date
WO2000032330A1 true WO2000032330A1 (fr) 2000-06-08

Family

ID=22746103

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1999/027802 WO2000032330A1 (fr) 1998-11-30 1999-11-23 Procede de fabrication de disques de frein

Country Status (6)

Country Link
EP (1) EP1140388A4 (fr)
JP (1) JP2002531266A (fr)
AU (1) AU2347000A (fr)
CA (1) CA2352238A1 (fr)
MX (1) MXPA01005401A (fr)
WO (1) WO2000032330A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10253833B2 (en) 2017-06-30 2019-04-09 Honda Motor Co., Ltd. High performance disc brake rotor
US11187290B2 (en) 2018-12-28 2021-11-30 Honda Motor Co., Ltd. Aluminum ceramic composite brake assembly

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5215143A (en) * 1992-11-16 1993-06-01 American Colloid Company Non-porous carbon molding (foundry) sand and method of casting
US5503214A (en) * 1994-04-04 1996-04-02 Cmi International, Inc. Mold and method for casting a disk brake rotor
US5862892A (en) * 1996-04-16 1999-01-26 Hayes Lemmerz International Inc. Composite rotor for caliper disc brakes

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5094289A (en) * 1990-09-19 1992-03-10 American Colloid Company Roasted carbon molding (foundry) sand and method of casting

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5215143A (en) * 1992-11-16 1993-06-01 American Colloid Company Non-porous carbon molding (foundry) sand and method of casting
US5503214A (en) * 1994-04-04 1996-04-02 Cmi International, Inc. Mold and method for casting a disk brake rotor
US5862892A (en) * 1996-04-16 1999-01-26 Hayes Lemmerz International Inc. Composite rotor for caliper disc brakes

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of EP1140388A4 *

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10253833B2 (en) 2017-06-30 2019-04-09 Honda Motor Co., Ltd. High performance disc brake rotor
US10550902B2 (en) 2017-06-30 2020-02-04 Honda Motor Co., Ltd. High performance disc brake rotor
US11187290B2 (en) 2018-12-28 2021-11-30 Honda Motor Co., Ltd. Aluminum ceramic composite brake assembly

Also Published As

Publication number Publication date
EP1140388A1 (fr) 2001-10-10
JP2002531266A (ja) 2002-09-24
CA2352238A1 (fr) 2000-06-08
EP1140388A4 (fr) 2002-03-27
AU2347000A (en) 2000-06-19
MXPA01005401A (es) 2003-03-27

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