BRAKE DISC TOOL FOR MACHINING A BRAKE DISC BLANK, BRAKE DISC PRODUCTION PLANT AND METHOD FOR PRODUCING A BRAKE DISC

• US 20190314897A1
• Filed: 08/14/2017
• Published: 10/17/2019
• Est. Priority Date: 08/25/2016
• Status: Active Grant

• Current Assignee: Ecoroll AG Werkzeugtechnik
• Original Assignee: Ecoroll AG Werkzeugtechnik
• Inventors: ROTTGER, Karsten, HENI, Zied
• Granted Patent: US 11,318,538 B2
• Time in Patent Office: Days
• CPC Class Codes: B23B 2235/045 Simultaneous machining of both sides of the brake disc
• CPC Class Codes: B23B 5/02 for turning hubs or brake drums B23B5/04 takes precedence
• CPC Class Codes: B23P 9/02 Treating or finishing by applying pressure, e.g. knurling B23P9/04 takes precedence
• CPC Class Codes: B24B 39/06 designed for working plane surfaces
• CPC Class Codes: F16D 2250/0038 Surface treatment
• CPC Class Codes: F16D 65/0043 Brake maintenance and assembly, tools therefor
• CPC Class Codes: F16D 65/12 Discs; Drums for disc brakes
• CPC Class Codes: F16D 65/127 characterised by properties of the disc surface; Discs lined with friction material

Abstract

The invention relates to a brake disc tool for machining a brake disc blank (12) with (a) a first cutting tool (14) which is arranged to cut a first brake surface (34) of the brake disc blank (12), (b) a second cutting tool (16) which is arranged to cut a second brake surface (36) of the brake disc blank (12), (c) a first forming tool (18) for forming the first brake surface (34), (d) a second forming tool (20) for forming the second brake surface (36), and (e) at least one infeed device (42) for the infeed of the cutting tools (14, 16) and the forming tools (18, 20) towards one another, such that a brake disc blank (12) arranged between the cutting tools (14, 16) and the forming tools (18, 20) is able to be machined and rolled in each case simultaneously on both of its brake surfaces (34, 36).

Claims

1. A brake disc tool for machining a brake disc blank, comprising:

(a) a first cutting tool which is arranged to cut a first brake surface of the brake disc blank,

(b) a second cutting tool which is arranged to cut a second brake surface of the brake disc blank,

(c) a first forming tool for forming the first brake surface,

(d) a second forming tool for forming the second brake surface,

(e) at least one infeed device for the infeed of one or more of the first and second cutting tools and one or more of the first and second forming tools towards one another, such that the brake disc blank, when arranged between either or both the first and second cutting tools and the first and second forming tools, is able to be machined and rolled in each case simultaneously on both the first and second brake surfaces.

2. The brake disc tool according to claim 1, wherein the first forming tool is a rolling tool which has at least one rolling element and/or the second forming tool is a rolling tool which has at least one rolling element.

3. The brake disc tool according to claim 1, wherein the at least one infeed device is designed for infeed of the first and second cutting tools and the first and second forming tools towards one another, such that the brake disc blank is able to be simultaneously machined on both the first and second brake surfaces and be simultaneously formed.

4. The brake disc tool according to claim 2 further comprising:

(a) a tool mount for fixing the brake disc tool to a machine tool,

(b) wherein the at least one infeed device comprises

a cutting tool infeed device for moving the first cutting tool relative to the tool mount and/or

a forming tool infeed device for moving the first forming tool, independently or dependently from the first cutting tool, relative to the tool mount.

5. A brake disc production system, comprising:

(a) a machine tool which has a brake disc rotation device for accommodating and rotating a brake disc blank about a rotational axis, wherein the rotational axis is the same axis about which a finished brake disc rotates during operation, and

(b) a brake disc tool according to claim 1 arranged in relation to the brake disc rotation device in such a way that the first and second brake surfaces of the brake disc blank which has been accommodated and rotated by the brake disc rotation device can be simultaneously machined by way of rotational machining and/or simultaneously machined by way of forming.

6. The brake disc production system according to claim 5, further comprising a control unit configured to automatically carry out a method which includes the steps:

(i) rotation of the brake disc blank by the brake disc rotation device and the simultaneous machining of the first and second brake surfaces by the first and second cutting tools, and

(ii) subsequent rotation of the brake disc blank by the brake disc rotation device and the simultaneous machining of the first and second brake surfaces by the first and second forming tools.

7. The brake disc production system according to claim 6, wherein the control unit is configured to automatically

move the first cutting tool during machining on a path that extends along a cutting tool line,

wherein the cutting tool line is at a distance from a rotational axis of a rotational movement which is less than half of an outer diameter of a hub section of the brake disc.

8. The brake disc production system according to claim 5, wherein the control unit is configured to automatically

move the first cutting tool during machining on a cutting tool path that extends along a cutting tool line,

wherein the cutting tool line is at a distance from a rotational axis of a rotational movement which is at least smaller than one twentieth of an outer diameter of a hub section of the brake disc.

9. The brake disc production system according to claim 5 wherein

the first forming tool is fixed in such a way that it moves on a forming tool path, which extends along a forming tool line, when the first cutting tool moves on a cutting tool path,

wherein the forming tool line is separated from a cutting tool line by a separating plane on which a rotational axis runs.

10. The brake disc production system according to claim 5 wherein

the first forming tool is guided relative to the first cutting tool, and/or

the second forming tool is guided relative to the second cutting tool.

11. The brake disc production system according to claim 5 wherein

the first forming tool and the first cutting tool are guided in such a way that they move towards each other during a radially inward movement and/or

the second forming tool and the second cutting tool are guided in such a way that they move towards each other during a radially inward movement.

12. A method for producing a brake disc, comprising:

using a machine tool which has a brake disc rotation device for accommodating and rotating a brake disc blank about a rotational axis, wherein the rotational axis is the same axis about which a finished brake disc rotates during operation, and

using a brake disc tool according to claim 1 arranged in relation to the brake disc rotation device in such a way that the first and second brake surfaces of the brake disc blank which has been accommodated and rotated by the brake disc rotation device can be simultaneously machined by way of rotational machining and/or simultaneously machined by way of forming.

13. The method according to claim 12, wherein

(i) the first cutting tool engages at a first cutting point of engagement which is at a first cutting distance from the rotational axis,

(ii) the second cutting tool engages to its deepest point at a second cutting point of engagement which is at a second cutting distance from the rotational axis,

(iii) the first forming tool engages at a first forming point of engagement which is at a first forming distance from the rotational axis,

(iv) the second forming tool engages at a second forming point of engagement which is at a second forming distance from the rotational axis, and

(v) the first and second cutting tools and the first and second forming tools are moved such that, at least when all tools are engaged,

a first difference in distance between the first cutting distance and a first forming distance and

a second difference in distance between the second cutting distance and a second forming distance

 

remains constant and/or is at the most as great as a radial distance between the first and second brake surfaces and a hub section of the brake disc blank which protrudes axially above a brake surface plane on which the first brake surface lies.

14. The method according to claim 12 further comprising

(i) infeeding of the first and second cutting tools and the first and second forming tools onto the first and second brake surfaces of the brake disc blank,

(ii) rotating of the brake disc blank, and

(iii) simultaneously cutting the first and second brake surfaces and simultaneously forming first and second brake surfaces.

15. The method according to claim 12 further comprising:

(i) infeeding of the first and second cutting tools, followed by

(ii) rotating of the brake disc blank in a first direction of rotation and the cutting of the brake surfaces, followed by

(iii) rotating the brake disc blank in an opposite direction of rotation and simultaneously forming the first and second brake surfaces.

16. The method according to claim 15 further comprising:

moving the first forming tool and the first cutting tool radially inwards with the same radial movement components, followed by

stopping of a radially inwards movement of the first cutting tool and

continued radially inwards movement of the first forming tool, and/or

moving the second forming tool and the second cutting tool radially inwards with the same radial movement components, followed by

stopping of a radially inwards movement of the second cutting tool and

continued radially inwards movement of the second forming tool.

17. The method according to claim 12 further comprising:

moving the first and second cutting tools and the first and second forming tools radially outwards such that they disengage,

engaging the first and second cutting tools and the first and second forming tools followed by

moving the first and second cutting tools and the first and second forming tools radially outwards and simultaneously cutting and forming of the brake surfaces.