US20090032211A1 - Method for securing an insert in the manufacture of a damped part - Google Patents
Method for securing an insert in the manufacture of a damped part Download PDFInfo
- Publication number
- US20090032211A1 US20090032211A1 US12/165,729 US16572908A US2009032211A1 US 20090032211 A1 US20090032211 A1 US 20090032211A1 US 16572908 A US16572908 A US 16572908A US 2009032211 A1 US2009032211 A1 US 2009032211A1
- Authority
- US
- United States
- Prior art keywords
- insert
- mold
- set forth
- magnet
- mold portion
- Prior art date
- Legal status (The legal status 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 status listed.)
- Abandoned
Links
- 238000000034 method Methods 0.000 title claims abstract description 33
- 238000004519 manufacturing process Methods 0.000 title claims description 10
- 239000000463 material Substances 0.000 claims abstract description 35
- 238000005266 casting Methods 0.000 claims abstract description 15
- 239000012768 molten material Substances 0.000 claims abstract description 9
- 239000002245 particle Substances 0.000 claims description 40
- 239000000835 fiber Substances 0.000 claims description 31
- 238000000576 coating method Methods 0.000 claims description 20
- 239000011248 coating agent Substances 0.000 claims description 19
- 229910001018 Cast iron Inorganic materials 0.000 claims description 7
- 229910001060 Gray iron Inorganic materials 0.000 claims description 7
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 7
- 229910045601 alloy Inorganic materials 0.000 claims description 7
- 239000000956 alloy Substances 0.000 claims description 7
- 229910052782 aluminium Inorganic materials 0.000 claims description 7
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 7
- 239000011156 metal matrix composite Substances 0.000 claims description 7
- 239000010935 stainless steel Substances 0.000 claims description 7
- 229910001220 stainless steel Inorganic materials 0.000 claims description 7
- 239000010959 steel Substances 0.000 claims description 7
- 239000010936 titanium Substances 0.000 claims description 7
- 229910052719 titanium Inorganic materials 0.000 claims description 7
- 238000003754 machining Methods 0.000 claims description 6
- 229910000831 Steel Inorganic materials 0.000 claims description 5
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 4
- 229910052749 magnesium Inorganic materials 0.000 claims description 4
- 239000011777 magnesium Substances 0.000 claims description 4
- 239000004576 sand Substances 0.000 claims description 2
- 238000007711 solidification Methods 0.000 claims description 2
- 230000008023 solidification Effects 0.000 claims description 2
- 230000003213 activating effect Effects 0.000 claims 1
- 238000013016 damping Methods 0.000 description 23
- 229910052751 metal Inorganic materials 0.000 description 17
- 239000002184 metal Substances 0.000 description 17
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 8
- 230000033001 locomotion Effects 0.000 description 8
- 239000011230 binding agent Substances 0.000 description 7
- 230000000295 complement effect Effects 0.000 description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 5
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 4
- 239000010439 graphite Substances 0.000 description 4
- 229910002804 graphite Inorganic materials 0.000 description 4
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 230000005540 biological transmission Effects 0.000 description 3
- 239000004927 clay Substances 0.000 description 3
- -1 magnesium-iron-aluminum Chemical compound 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 229910001208 Crucible steel Inorganic materials 0.000 description 2
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 2
- 229910052581 Si3N4 Inorganic materials 0.000 description 2
- YKTSYUJCYHOUJP-UHFFFAOYSA-N [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] Chemical compound [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] YKTSYUJCYHOUJP-UHFFFAOYSA-N 0.000 description 2
- 238000005422 blasting Methods 0.000 description 2
- 229920005551 calcium lignosulfonate Polymers 0.000 description 2
- RYAGRZNBULDMBW-UHFFFAOYSA-L calcium;3-(2-hydroxy-3-methoxyphenyl)-2-[2-methoxy-4-(3-sulfonatopropyl)phenoxy]propane-1-sulfonate Chemical compound [Ca+2].COC1=CC=CC(CC(CS([O-])(=O)=O)OC=2C(=CC(CCCS([O-])(=O)=O)=CC=2)OC)=C1O RYAGRZNBULDMBW-UHFFFAOYSA-L 0.000 description 2
- 229910052570 clay Inorganic materials 0.000 description 2
- 229910052878 cordierite Inorganic materials 0.000 description 2
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 description 2
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 2
- 238000005553 drilling Methods 0.000 description 2
- 238000005242 forging Methods 0.000 description 2
- 238000000227 grinding Methods 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 238000003801 milling Methods 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 229910052863 mullite Inorganic materials 0.000 description 2
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 description 2
- 229910052615 phyllosilicate Inorganic materials 0.000 description 2
- 229910010271 silicon carbide Inorganic materials 0.000 description 2
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 2
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 2
- 229910001928 zirconium oxide Inorganic materials 0.000 description 2
- 229920001732 Lignosulfonate Polymers 0.000 description 1
- 239000004115 Sodium Silicate Substances 0.000 description 1
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 238000005524 ceramic coating Methods 0.000 description 1
- 238000003486 chemical etching Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 229910052906 cristobalite Inorganic materials 0.000 description 1
- 238000004512 die casting Methods 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 235000013312 flour Nutrition 0.000 description 1
- 125000000524 functional group Chemical group 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 230000013011 mating Effects 0.000 description 1
- 239000002557 mineral fiber Substances 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 239000011819 refractory material Substances 0.000 description 1
- 238000005488 sandblasting Methods 0.000 description 1
- 239000012056 semi-solid material Substances 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 235000019351 sodium silicates Nutrition 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
- 229910001845 yogo sapphire Inorganic materials 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/20—Accessories: Details
- B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
- B22D17/24—Accessories for locating and holding cores or inserts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
Definitions
- the field to which the disclosure generally relates includes a method of manufacturing a damped part including an insert.
- Parts subjected to vibration may produce unwanted or undesirable vibrations.
- a part or component may be set into motion at an undesirable frequency for a prolonged period.
- parts such as brake rotors, brackets, pulleys, brake drums, transmission housings, gears, and other parts may contribute to noise that gets transmitted to the passenger compartment of a vehicle.
- a variety of techniques have been employed, including the use of polymer coatings on engine parts, sound absorbing barriers, and laminated panels having visco elastic layers.
- the undesirable vibrations in parts or components may occur in a variety of other products including, but not limited to, sporting equipment, household appliances, manufacturing equipment such as lathes, milling/grinding/drilling machines, earth moving equipment, other non-automotive applications, and components that are subject to dynamic loads and vibration. These components can be manufactured through a variety of means including casting, machining, forging, welding, die-casting, etc.
- One embodiment of the invention includes a method including providing an insert, wherein at least a portion of the insert is attracted to a magnet; providing a mold including a first mold portion, a second mold portion, and a magnet having at least a portion thereof in or adjacent to at least one of the first mold portion or the second mold portion; positioning the insert in one of the mold portions such that the at least one magnet at least assists in holding the insert in place; and closing the mold and casting a molten material into the mold and around or adjacent to at least a portion of the insert and solidifying the material.
- FIG. 1 illustrates a product according to one embodiment of the invention
- FIG. 2 illustrates a product according to another embodiment of the invention
- FIG. 3 illustrates a product and a method, according to one embodiment of the invention
- FIG. 4 illustrates a product and a method, according to one embodiment of the invention
- FIG. 5 illustrates a product and a method according to one embodiment of the invention
- FIG. 6 illustrates a product and a method according to one embodiment of the invention
- FIG. 7 illustrates a product and a method according to one embodiment of the invention
- FIG. 8 illustrates a product and a method according to one embodiment of the invention
- FIG. 9 is a sectional view with portions broken away of one embodiment of the invention including an insert
- FIG. 10 is a sectional view with portions broken away of one embodiment of the invention including an insert having a layer thereon to provide a frictional surface or damping;
- FIG. 11 is an enlarged view of one embodiment of the invention.
- FIG. 12 is a sectional view with portions broken away of one embodiment of the invention.
- FIG. 13 is an enlarged sectional view with portions broken away of one embodiment of the invention.
- FIG. 14 is an enlarged sectional view with portions broken away of one embodiment of the invention.
- FIG. 15 is an enlarged sectional view with portions broken away of one embodiment of the invention.
- FIG. 16 illustrates one embodiment of the invention
- FIG. 17 is a sectional view with portions broken away of one embodiment of the invention.
- FIG. 18 is a sectional view with portions broken away of one embodiment of the invention.
- FIG. 19 is a plan view with portions broken away illustrating one embodiment of the invention.
- FIG. 20 is a sectional view taken along line 20 - 20 of FIG. 19 illustrating one embodiment of the invention.
- FIG. 21 is a sectional view with portions broken away illustrating one embodiment of the invention.
- FIG. 22 is a sectional view with portions broken away illustrating another embodiment of the invention.
- an exemplary product produced by an embodiment of the invention may include a product or part 500 .
- the part 500 may be a rotor assembly 12 .
- the product or part 500 may be, for example, but is not limited to a bracket, pulley, brake drum, transmission housing, gear, motor housing, shaft, bearing, engine, baseball bat, lathe machine, milling machine, drilling machine, or grinding machine.
- the rotor assembly 12 may include a hub portion 14 , a first rotor cheek 16 , and an insert 18 .
- the insert 18 may or may not be coextensive with the first rotor cheek 16 .
- the insert may be completely encapsulated by the first rotor cheek 16 .
- the insert 18 may be annular or it may take other suitable shapes.
- the first rotor cheek 16 may include a first cheek face 20 and a second cheek face 22 .
- the hub portion 14 may include a central aperture 24 .
- the hub portion 14 may also include a plurality of bolt holes 26 .
- the hub portion 14 and the first rotor cheek 16 may comprise one of cast iron, gray cast iron, titanium, aluminum, steel, stainless steel, any of a variety of other alloys, or metal matrix composite. At least a portion of the insert 18 may comprise a material attracted to a magnet.
- the insert 18 may comprise at least one of a ferrous based material including, but not limited to, cast iron, gray cast iron, steel, or stainless steel, or a nonferrous based material including, but not limited to, aluminum, magnesium, or titanium, or any of a variety of other alloys, or metal matrix composite.
- the insert 18 may be about 0.1 mm to about 20 mm thick.
- the insert 18 may include a coating. In one embodiment, the coating may prevent cast metal from bonding to the insert during the manufacturing process, in order to ensure that the insert dampens the vibration of the product using frictional or Coulomb damping.
- the rotor assembly 12 may be vented and may include a first rotor cheek 16 with a first cheek face 20 and a second rotor cheek 17 with a second cheek face 22 .
- the first cheek face 20 and the second cheek face 22 may be separated by a plurality of vanes 28 therebetween.
- the insert 18 may be located in the first rotor cheek 16 .
- the insert 18 may be located in the second rotor cheek 17 .
- an insert 18 may be located in each of the first rotor cheek 16 and the second rotor cheek 17 .
- the mold 30 may include a first mold portion or shell 32 and a second mold portion or shell 34 .
- the orientation of the mold 30 may be vertical. In other embodiments, the orientation of the mold 30 may be horizontal. In various embodiments, the orientation of the mold 30 may be at any suitable angle.
- the first mold portion 32 and the second mold portion 34 are configured to manufacture the part 500 .
- the two portions of the mold 32 and 34 form a cavity 36 for casting the part 500 .
- the first mold portion 32 and the second mold portion 34 may be sand molds.
- the first mold portion 32 may also include a generally cylindrical protrusion 38 configured to produce the central aperture 24 on the part 500 (shown in FIGS. 1-2 ). But in other embodiments, the central aperture 24 may be produced by a subsequent machining process.
- the plurality of bolt holes 26 (shown in FIGS. 1-2 ) may be produced by a plurality of smaller protrusions (not shown) in the first mold portion 32 or by a subsequent machining process.
- FIG. 3 also shows the insert 18 positioned within the second mold portion 34 .
- the insert 18 may have a variety of geometries and is not limited to the embodiment shown in the drawings.
- the insert 18 may have a plurality of tabs 40 which rest on cutout portions 42 of the second mold portion 34 .
- the insert 18 may have any suitable number of tabs 40 which may extend from a main body portion, for example, the tabs 40 may extend radially inward or outward from an annular body portion.
- the insert 18 but not the tabs 40 may have a coating over a portion thereof.
- the insert 18 and the tabs 40 may have a coating over at least a portion thereof.
- the tabs 40 may have any suitable shape.
- the tabs 40 may be the shape of a square, rectangle, triangle, semi-circle, or oval.
- the insert 18 may not have tabs 40 or it may have a small number of tabs 40 .
- the first mold portion 32 may include at least one magnet 44 .
- the magnet 44 may be used to position the insert 18 in the second mold portion 34 and secure the insert 18 in the second mold portion 34 during the molding and casting process. In one embodiment, the magnet 44 may at least assist in holding the insert 18 in place.
- the loading of the insert 18 into the mold 30 may be manual or automatic.
- the loading of the magnet 44 into the mold 30 may be manual or automatic.
- the magnet 44 may be an electromagnet.
- the magnet 44 may be instrumented and activated after loading the insert 18 and while closing the second mold portion 34 .
- the magnet 44 may be any suitable shape, for example, the shape of a circle, oval, triangle, square, rectangle, or Y-shape. In one embodiment, the magnet 44 may be the same general shape as the insert 18 .
- the magnet 44 may be positioned inside the first mold portion 32 with an end magnet portion 45 extending beyond the first mold portion 32 .
- the magnet 44 may be removed from the first mold portion 32 using the end magnet portion 45 , for example by pulling the magnet 44 out of the first mold portion by pulling the end magnet portion 45 .
- the magnet 44 may be positioned inside the second mold portion 34 at a distance 46 from the edge of the second mold portion 34 that will allow the magnet 44 to at least assist in securing the insert 18 . In other embodiments, the magnet 44 may be positioned at any suitable location that will allow the magnet 44 to at least assist in securing the insert 18 in the mold 30 .
- the electromagnet may be activated after the insert is loaded onto the second mold portion 34 .
- the electromagnet may then at least assist in holding the insert in place until the first mold portion 32 engages the second mold portion 34 , as shown in FIGS. 5-6 .
- the magnet 44 may be removed from the mold 30 before the material 60 is introduced into the mold 30 .
- the removal of the magnet 44 from the mold 30 may be manual or automatic.
- the magnet 44 may be removed from the first mold portion 32 using the end magnet portion 45 , for example by pulling the magnet 44 out of the first mold portion by pulling the end magnet portion 45 .
- the magnet 44 has already been removed.
- the magnet 44 may be positioned adjacent the first mold portion 32 or second mold portion 34 to hold the insert 18 in place.
- a compressive force may be applied to the first mold portion 32 and the second mold portion 34 , for example to push the mold portions 32 and 34 together.
- the tabs 40 of the insert 18 may be supported between the cutout portions 42 of the second mold portion 34 and lands 48 of the first mold portion 32 .
- the material 60 is then introduced, for example injected, into the cavity 36 to form the part 500 .
- the material 60 may be cast (charging) into the mold and around or immediately adjacent to at least a portion of the insert or a coating thereon.
- the material 60 may be one of cast iron, gray cast iron, aluminum, steel, titanium, stainless steel, any of a variety of other alloys, or metal matrix composite.
- the material 60 may be molten.
- the material 60 is a semi-solid material and may be introduced into the cavity 36 in accordance with the well known semi-solid forging process.
- the material 60 may be introduced into the mold 30 by any suitable method.
- the mold portions 32 and 34 may be attached to a molding device with ingates for the material 60 , and the material 60 may enter the mold through the ingates (not shown).
- the material 60 may be introduced through a first inlet 64 into a first channel 62 .
- the magnet 44 may be removed from the mold 30 before the material 60 is introduced through the first inlet 64 into the first channel 62 .
- the first channel 62 may extend through a portion of both the first mold portion 32 and the second mold portion 34 .
- the material 60 may be introduced through a second inlet 66 into a second channel 68 in the second mold portion 34 .
- the magnet 44 may be removed from the mold 30 before the material 60 is introduced through the second inlet 66 into the second channel 68 .
- the material 60 may be introduced through any inlet located in a suitable place on the mold 30 .
- the second channel 68 may extend through a portion of both the first mold portion 32 and the second mold portion 34 .
- the part 500 is a rotor assembly 12 and includes the hub portion 14 , the first rotor cheek 16 , and the insert 18 .
- the part 500 may then be further machined. For example, the tabs 40 may be machined off.
- the next insert 18 may be positioned in the open mold 30 and the manufacturing process of the part 500 may repeat.
- one embodiment of the invention includes a product or part 500 having a frictional damping means.
- the frictional damping means may be used in a variety of applications including, but not limited to, applications where it is desirable to reduce noise associated with a vibrating part or reduce the vibration amplitude and/or duration of a part that is struck, dynamically loaded, excited, or set in motion.
- the frictional damping means may include an interface boundary conducive to frictionally damping a vibrating part.
- the damping means may include frictional surfaces 502 constructed and arranged to move relative to each other and in frictional contact, so that vibration of the part is dissipated by frictional damping due to the frictional movement of the surfaces 502 against each other.
- frictional damping may be achieved by the movement of the frictional surfaces 502 against each other.
- the movement of frictional surfaces 502 against each other may include the movement of: surfaces of the body 506 of the part against each other; a surface of the body 506 of the part against a surface of the insert 18 ; a surface of the body 506 of the part against the layer 520 ; a surface of the insert 18 against the layer 520 ; a surface of the body 506 of the part against the particles 514 or fibers; a surface of the insert 18 against the particles 514 or fibers; or by frictional movement of the particles 514 or fibers against each other or against remaining binder material.
- the frictional surface 502 may have a minimal area over which frictional contact may occur that may extend in a first direction a minimum distance of 0.1 mm and/or may extend in a second (generally traverse) direction a minimum distance of 0.1 mm.
- the insert 18 may be an annular body and the area of frictional contact on a frictional surface 502 may extend in an annular direction a distance ranging from about 20 mm to about 1000 mm and in a transverse direction ranging from about 10 mm to about 75 mm.
- the frictional surface 502 may be provided in a variety of embodiments, for example, as illustrated in FIGS. 9-22 .
- one or more of the outer surfaces 522 , 524 of the insert 18 or surfaces 526 , 528 of the body 506 of the part 500 may include a relatively rough surface including a plurality of peaks 510 and valleys 512 to enhance the frictional damping of the part.
- the surface of the insert 18 or the body 506 may be abraded by sandblasting, glass bead blasting, water jet blasting, chemical etching, machining or the like.
- Each frictional surface 502 may have a plurality of peaks 510 and a plurality of valleys 512 .
- the depth as indicated by line V of the valleys 512 may vary with embodiments.
- the average of the depth V of the valleys 512 may range from about 1 ⁇ m-300 ⁇ m, 50 ⁇ m-260 ⁇ m, 100 ⁇ m-160 ⁇ m or variations of these ranges. However, for all cases there is local contact between the opposing frictional surfaces 502 during component operation for frictional damping to occur.
- the damping means or frictional surface 502 may be provided by particles 514 or fibers provided on at least one face of the insert 18 or a surface of the body 506 of the part 500 .
- the particles 514 may have an irregular shape (e.g., not smooth) to enhance frictional damping, as illustrated in FIG. 16 .
- One embodiment of the invention may include a layer 520 including the particles 514 or fibers which may be bonded to each other or to a surface of the body 506 of the part or a surface of the insert 18 due to the inherent bonding properties of the particles 514 or fibers.
- the bonding properties of the particles 514 or fibers may be such that the particles 514 or fibers may bind to each other or to the surfaces of the body 506 or the insert 18 under compression.
- the particles 514 or the fibers may be treated to provide a coating thereon or to provide functional groups attached thereto to bind the particles together or attach the particles to at least one of a surface of the body 506 or a surface of the insert 18 .
- the particles 514 or fibers may be embedded in at least one of the body 506 of the part or the insert 18 to provide the frictional surface 502 ( FIGS. 11-12 ).
- the insert 18 and/or particles 514 or fibers may be made from materials capable of resisting flow or resisting significant erosion during the manufacturing.
- the insert 18 and/or the particles 514 or fibers may include refractory materials capable of resisting flow or that do not significantly erode at temperatures above 1100° F., above 2400° F., or above 2700° F.
- the insert 18 or the particles 514 should not be wet by the molten material so that the molten material does not bond to the insert 18 or layer 520 at locations wherein a frictional surface 502 for providing frictional damping is desired.
- suitable particles 514 or fibers include, but are not limited to, particles or fibers including silica, alumina, graphite with clay, silicon carbide, silicon nitride, cordierite (magnesium-iron-aluminum silicate), mullite (aluminum silicate), zirconia (zirconium oxide), phyllosilicates, or other high-temperature-resistant particles.
- the particles 514 may have a length along the longest dimension thereof ranging from about 1 ⁇ m-350 ⁇ m, or 10 ⁇ m-250 ⁇ m.
- the layer 520 may be a coating over the body 506 of the part or the insert 18 .
- the coating may include a plurality of particles 514 which may be bonded to each other and/or to the surface of the body 506 of the part or the insert 18 by an inorganic or organic binder 516 ( FIGS. 10 , 15 ) or other bonding materials.
- suitable binders include, but are not limited to, epoxy resins, phosphoric acid binding agents, calcium aluminates, sodium silicates, wood flour, or clays.
- the particles 514 may be held together and/or adhered to the body 506 or the insert 18 by an inorganic binder.
- the coating may be deposited on the insert 18 or body 506 as a liquid dispersed mixture of alumina-silicate-based, organically bonded refractory mix.
- the coating may include at least one of alumina or silica particles, mixed with a lignosulfonate binder, cristobalite (SiO 2 ), quartz, or calcium lignosulfonate.
- the calcium lignosulfonate may serve as a binder.
- the coating may include IronKote.
- a liquid coating may be deposited on a portion of the insert and may include any high temperature ceramic coating, such as but not limited to, Ladle Kote 310 B.
- the coating may include at least one of clay, Al 2 O 3 , SiO 2 , a graphite and clay mixture, silicon carbide, silicon nitride, cordierite (magnesium-iron-aluminum silicate), mullite (aluminum silicate), zirconia (zirconium oxide), or phyllosilicates.
- the coating may comprise a fiber such as ceramic or mineral fibers.
- the thickness L of the layer 520 , particles 514 and/or fibers may vary.
- the thickness L of the layer 520 , particles 514 and/or fibers may range from about 1 ⁇ m-400 ⁇ m, 10 ⁇ m-400 ⁇ m, 30 ⁇ m-300 ⁇ m, 30 ⁇ m-40 ⁇ m, 40 ⁇ m-100 ⁇ m, 100 ⁇ m-120 ⁇ m, 120 ⁇ m-200 ⁇ m, 200 ⁇ m-300 ⁇ m, 200 ⁇ m-250 ⁇ m, or variations of these ranges.
- the particles 514 or fibers may be temporarily held together and/or to the surface of the insert 18 by a fully or partially sacrificial coating.
- the sacrificial coating may be consumed by molten metal or burnt off when metal is cast around or over the insert 18 .
- the particles 514 or fibers are left behind trapped between the body 506 of the cast part and the insert 18 to provide a layer 520 consisting of the particles 514 or fibers or consisting essentially of the particles 514 or fibers.
- the layer 520 may be provided over the entire insert 18 or only over a portion thereof.
- the insert 18 may include a tab 534 ( FIG. 10 ).
- the insert 18 may include an annular body portion and a tab 534 extending radially inward or outward therefrom.
- at least one wettable surface 536 of the tab 534 does not include a layer 520 including particles 514 or fibers, or a wettable material such as graphite is provided over the tab 534 , so that the cast metal is bonded to the wettable surface 536 to attach the insert 18 to the body 506 of the part 500 but still allow for frictional damping over the remaining insert surface which is not bonded to the casting.
- At least a portion of the insert 18 is treated or the properties of the insert 18 are such that molten metal will not wet or bond to that portion of the insert 18 upon solidification of the molten metal.
- at least one of the body 506 of the part or the insert 18 includes a metal, for example, but not limited to, a ferrous based material including, but not limited to, cast iron, gray cast iron, steel, or stainless steel, or a non-ferrous based material including, but not limited to, aluminum, magnesium, or titanium, or any of a variety of other alloys, or metal matrix composite including abrasive particles.
- the insert 18 may include a material such as a metal having a higher melting point than the melting point of the molten material being cast around a portion thereof.
- the insert 18 may have a minimum average thickness of 0.2 mm and/or a minimum width of 0.1 mm and/or a minimum length of 0.1 mm. In another embodiment the insert 18 may have a minimum average thickness of 0.2 mm and/or a minimum width of 2 mm and/or a minimum length of 5 mm. In other embodiments the insert 18 may have a thickness ranging from about 0.1-20 mm, 0.1-6.0 mm, or 1.0-2.5 mm, or ranges therebetween.
- the frictional surface 502 may have a plurality of peaks 510 and a plurality of valleys 512 .
- the depth as indicated by line V of the valleys 512 may vary with embodiments.
- the average of the depth V of the valleys 512 may range from about 1 ⁇ m-300 ⁇ m, 50 ⁇ m-260 ⁇ m, 100 ⁇ m-160 ⁇ m or variations of these ranges.
- improvements in the frictional damping may be achieved by adjusting the thickness (L, as shown in FIG. 10 ) of the layer 520 , or by adjusting the relative position of opposed frictional surfaces 502 or the average depth of the valleys 512 .
- the insert 18 is not pre-loaded or under pre-tension or held in place by tension. In one embodiment the insert 18 is not a spring.
- Another embodiment of the invention includes a process of casting a material comprising a metal around an insert 18 with the proviso that the frictional surface 502 portion of the insert used to provide frictional damping is not captured and enclosed by a sand core that is placed in the casting mold.
- the insert 18 or the layer 520 includes at least one frictional surface 502 or two opposite friction surfaces 502 that are completely enclosed by the body 506 of the part.
- the layer 520 and/or insert 18 does not include or is not carbon paper or cloth.
- the insert 18 may include a first face 522 and an opposite second face 524 and the body 506 of the part may include a first inner face 526 adjacent the first face 522 of the insert 18 constructed to be complementary thereto, for example nominally parallel thereto.
- the body 506 of the part includes a second inner face 528 adjacent to the second face 524 of the insert 18 constructed to be complementary thereto, for example parallel thereto.
- the body 506 may include a first outer face 530 overlying the first face 522 of the insert 18 constructed to be complementary thereto, for example parallel thereto.
- the body 506 may include a first outer face 532 overlying the second face 524 of the insert 18 constructed to be complementary thereto, for example parallel thereto.
- the outer faces 530 , 532 of the body 506 are not complementary to associated faces 522 , 524 of the insert 18 .
- the slot-like feature 508 may be defined in part by a first inner face 526 and a second inner face 528 which may be constructed to be complementary to each other, for example parallel to each other.
- the surfaces 526 and 528 ; 526 and 522 ; or 528 and 524 are mating surfaces but not parallel to each other.
- the insert 18 may be an inlay wherein a first face 522 thereof is not enclosed by the body 506 of the part.
- the insert 18 may include a tang or tab 534 which may be bent downward as shown in FIG. 17 .
- a wettable surface 536 may be provided that does not include a layer 520 including particles 514 or fibers, or a wettable material such as graphite is provided over the tab 534 , so that the cast metal is bonded to the wettable surface 536 to attach the insert 18 to the body of the part but still allow for frictional damping on the non-bonded surfaces.
- a layer 520 including particles 514 or fibers may underlie the portion of the second face 524 of the insert 18 not used to make the bent tab 534 .
- the insert 18 includes a tab 534 which may be formed by machining a portion of the first face 522 of the insert 18 ( FIG. 18 ).
- the tab 534 may include a wettable surface 536 having cast metal bonded thereto to attach the insert 18 to the body of the part but still allow for friction damping by way of the non-bonded surfaces.
- a layer 520 including particles 514 or fibers may underlie the entire second face 524 or a portion thereof.
- all surfaces including the tabs 534 may be non-wettable, for example by way of a coating 520 thereon, and features of the body portion 506 such as, but not limited to, a shoulder 537 may be used to hold the insert 18 in place.
- one embodiment of the invention may include a part 500 having a body portion 506 and an insert 18 enclosed by the body part 506 .
- the insert 18 may include through holes formed therein so that a stake or post 540 extends into or through the insert 18 .
- a layer 520 including a plurality of particles 514 or fibers may be provided over at least a portion of the insert 18 to provide a frictional surface 502 and to prevent bonding thereto by cast metal.
- the insert 18 including the layer 520 may be placed in a casting mold and molten metal may be poured into the casting mold and solidified to form the post 540 extending through the insert 18 .
- An inner surface 542 defining the through hole of the insert 18 may be free of the layer 520 or may include a wettable material thereon so that the post 540 is bonded to the insert 18 .
- the post 18 may not be bonded the insert 18 at the inner surface 542 .
- the insert 18 may include a feature such as, but not limited to, a shoulder 505 and/or the post 540 may include a feature such as, but not limited to, a shoulder 537 to hold the insert in place.
- the insert may be provided as an inlay in a casting including a body portion 506 and may include a post 540 extending into or through the insert 18 .
- the insert 18 may be bonded to the post 540 to hold the insert in place and still allow for frictional damping.
- the insert 18 may include a recess defined by an inner surface 542 of the insert 18 and a post 540 may extend into the insert 18 but not extend through the insert 18 .
- the post 18 may not be bonded to the insert 18 at the inner surface 542 .
- the insert 18 may include a feature such as, but not limited to, a shoulder 505 and/or the post 540 may include a feature such as, but not limited to, a shoulder 537 to hold the insert in place.
- an insert 18 or substrate may be provided over an outer surface 530 of the body portion 506 .
- a layer 520 may or may not be provided between the insert 18 and the outer surface 530 .
- the insert 18 may be constructed and arranged with through holes formed therethrough or through a recess therein so that cast metal may extend into or through the insert 18 to form a post 540 to hold the insert in position and still allow for frictional damping.
- the post 540 may or may not be bonded to the insert 18 as desired.
- the post 540 may extend through the insert 18 and join another portion of the body 506 if desired.
- first layer or component When the term “over,” “overlying,” overlies,” “under,” “underlying,” or “underlies” is used herein to describe the relative position of a first layer or component with respect to a second layer or component such shall mean the first layer or component is directly on and in direct contact with the second layer or component or that additional layers or components may be interposed between the first layer or component and the second layer or component.
Abstract
Description
- This application claims the benefit of U.S. Provisional Application No. 60/953,793, filed Aug. 3, 2007.
- The field to which the disclosure generally relates includes a method of manufacturing a damped part including an insert.
- Parts subjected to vibration may produce unwanted or undesirable vibrations. Similarly, a part or component may be set into motion at an undesirable frequency for a prolonged period. For example, parts such as brake rotors, brackets, pulleys, brake drums, transmission housings, gears, and other parts may contribute to noise that gets transmitted to the passenger compartment of a vehicle. In an effort to reduce the generation of this noise and thereby its transmission into the passenger compartment, a variety of techniques have been employed, including the use of polymer coatings on engine parts, sound absorbing barriers, and laminated panels having visco elastic layers. The undesirable vibrations in parts or components may occur in a variety of other products including, but not limited to, sporting equipment, household appliances, manufacturing equipment such as lathes, milling/grinding/drilling machines, earth moving equipment, other non-automotive applications, and components that are subject to dynamic loads and vibration. These components can be manufactured through a variety of means including casting, machining, forging, welding, die-casting, etc.
- One embodiment of the invention includes a method including providing an insert, wherein at least a portion of the insert is attracted to a magnet; providing a mold including a first mold portion, a second mold portion, and a magnet having at least a portion thereof in or adjacent to at least one of the first mold portion or the second mold portion; positioning the insert in one of the mold portions such that the at least one magnet at least assists in holding the insert in place; and closing the mold and casting a molten material into the mold and around or adjacent to at least a portion of the insert and solidifying the material.
- Other exemplary embodiments of the invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while disclosing exemplary embodiments of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
- Exemplary embodiments of the present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
-
FIG. 1 illustrates a product according to one embodiment of the invention; -
FIG. 2 illustrates a product according to another embodiment of the invention; -
FIG. 3 illustrates a product and a method, according to one embodiment of the invention; -
FIG. 4 illustrates a product and a method, according to one embodiment of the invention; -
FIG. 5 illustrates a product and a method according to one embodiment of the invention; -
FIG. 6 illustrates a product and a method according to one embodiment of the invention; -
FIG. 7 illustrates a product and a method according to one embodiment of the invention; -
FIG. 8 illustrates a product and a method according to one embodiment of the invention; -
FIG. 9 is a sectional view with portions broken away of one embodiment of the invention including an insert; -
FIG. 10 is a sectional view with portions broken away of one embodiment of the invention including an insert having a layer thereon to provide a frictional surface or damping; -
FIG. 11 is an enlarged view of one embodiment of the invention; -
FIG. 12 is a sectional view with portions broken away of one embodiment of the invention; -
FIG. 13 is an enlarged sectional view with portions broken away of one embodiment of the invention; -
FIG. 14 is an enlarged sectional view with portions broken away of one embodiment of the invention; -
FIG. 15 is an enlarged sectional view with portions broken away of one embodiment of the invention; -
FIG. 16 illustrates one embodiment of the invention; -
FIG. 17 is a sectional view with portions broken away of one embodiment of the invention; -
FIG. 18 is a sectional view with portions broken away of one embodiment of the invention; -
FIG. 19 is a plan view with portions broken away illustrating one embodiment of the invention; -
FIG. 20 is a sectional view taken along line 20-20 ofFIG. 19 illustrating one embodiment of the invention; -
FIG. 21 is a sectional view with portions broken away illustrating one embodiment of the invention; and -
FIG. 22 is a sectional view with portions broken away illustrating another embodiment of the invention. - The following description of the embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
- In one embodiment of the invention, a method of manufacturing a product is provided. Referring to
FIG. 1 , an exemplary product produced by an embodiment of the invention may include a product orpart 500. In one embodiment, thepart 500 may be arotor assembly 12. In various other embodiments (not shown), the product orpart 500 may be, for example, but is not limited to a bracket, pulley, brake drum, transmission housing, gear, motor housing, shaft, bearing, engine, baseball bat, lathe machine, milling machine, drilling machine, or grinding machine. Therotor assembly 12 may include ahub portion 14, afirst rotor cheek 16, and aninsert 18. Theinsert 18 may or may not be coextensive with thefirst rotor cheek 16. In one embodiment (not shown), the insert may be completely encapsulated by thefirst rotor cheek 16. Theinsert 18 may be annular or it may take other suitable shapes. - The
first rotor cheek 16 may include afirst cheek face 20 and asecond cheek face 22. In one embodiment, thehub portion 14 may include acentral aperture 24. Thehub portion 14 may also include a plurality ofbolt holes 26. Thehub portion 14 and thefirst rotor cheek 16 may comprise one of cast iron, gray cast iron, titanium, aluminum, steel, stainless steel, any of a variety of other alloys, or metal matrix composite. At least a portion of theinsert 18 may comprise a material attracted to a magnet. In various embodiments, at least a portion of theinsert 18 may comprise at least one of a ferrous based material including, but not limited to, cast iron, gray cast iron, steel, or stainless steel, or a nonferrous based material including, but not limited to, aluminum, magnesium, or titanium, or any of a variety of other alloys, or metal matrix composite. In one embodiment, theinsert 18 may be about 0.1 mm to about 20 mm thick. Theinsert 18 may include a coating. In one embodiment, the coating may prevent cast metal from bonding to the insert during the manufacturing process, in order to ensure that the insert dampens the vibration of the product using frictional or Coulomb damping. - In another embodiment shown in
FIG. 2 , therotor assembly 12 may be vented and may include afirst rotor cheek 16 with afirst cheek face 20 and asecond rotor cheek 17 with asecond cheek face 22. Thefirst cheek face 20 and thesecond cheek face 22 may be separated by a plurality ofvanes 28 therebetween. Theinsert 18 may be located in thefirst rotor cheek 16. In another embodiment (not shown), theinsert 18 may be located in thesecond rotor cheek 17. In yet another embodiment (not shown), aninsert 18 may be located in each of thefirst rotor cheek 16 and thesecond rotor cheek 17. - Referring to
FIGS. 3-4 , products and methods for casting thepart 500 including theinsert 18 are provided. The method may secure and position theinsert 18 in amold 30 in order to prevent any undesirable movement during assembly of themold 30 and subsequent introduction of amaterial 60 into themold 30. Referring toFIG. 3 , themold 30 may include a first mold portion orshell 32 and a second mold portion orshell 34. In some embodiments, the orientation of themold 30 may be vertical. In other embodiments, the orientation of themold 30 may be horizontal. In various embodiments, the orientation of themold 30 may be at any suitable angle. - The
first mold portion 32 and thesecond mold portion 34 are configured to manufacture thepart 500. The two portions of themold cavity 36 for casting thepart 500. In one embodiment, thefirst mold portion 32 and thesecond mold portion 34 may be sand molds. Thefirst mold portion 32 may also include a generallycylindrical protrusion 38 configured to produce thecentral aperture 24 on the part 500 (shown inFIGS. 1-2 ). But in other embodiments, thecentral aperture 24 may be produced by a subsequent machining process. In one embodiment, the plurality of bolt holes 26 (shown inFIGS. 1-2 ) may be produced by a plurality of smaller protrusions (not shown) in thefirst mold portion 32 or by a subsequent machining process. -
FIG. 3 also shows theinsert 18 positioned within thesecond mold portion 34. Theinsert 18 may have a variety of geometries and is not limited to the embodiment shown in the drawings. In one embodiment, theinsert 18 may have a plurality oftabs 40 which rest oncutout portions 42 of thesecond mold portion 34. Theinsert 18 may have any suitable number oftabs 40 which may extend from a main body portion, for example, thetabs 40 may extend radially inward or outward from an annular body portion. In one embodiment, theinsert 18 but not thetabs 40 may have a coating over a portion thereof. In another embodiment, theinsert 18 and thetabs 40 may have a coating over at least a portion thereof. Thetabs 40 may have any suitable shape. For example, thetabs 40 may be the shape of a square, rectangle, triangle, semi-circle, or oval. However, in other embodiments, theinsert 18 may not havetabs 40 or it may have a small number oftabs 40. - Still referring to
FIG. 3 , thefirst mold portion 32 may include at least onemagnet 44. Themagnet 44 may be used to position theinsert 18 in thesecond mold portion 34 and secure theinsert 18 in thesecond mold portion 34 during the molding and casting process. In one embodiment, themagnet 44 may at least assist in holding theinsert 18 in place. The loading of theinsert 18 into themold 30 may be manual or automatic. The loading of themagnet 44 into themold 30 may be manual or automatic. - In one embodiment, the
magnet 44 may be an electromagnet. Themagnet 44 may be instrumented and activated after loading theinsert 18 and while closing thesecond mold portion 34. Themagnet 44 may be any suitable shape, for example, the shape of a circle, oval, triangle, square, rectangle, or Y-shape. In one embodiment, themagnet 44 may be the same general shape as theinsert 18. Themagnet 44 may be positioned inside thefirst mold portion 32 with anend magnet portion 45 extending beyond thefirst mold portion 32. Themagnet 44 may be removed from thefirst mold portion 32 using theend magnet portion 45, for example by pulling themagnet 44 out of the first mold portion by pulling theend magnet portion 45. Themagnet 44 may be positioned inside thesecond mold portion 34 at adistance 46 from the edge of thesecond mold portion 34 that will allow themagnet 44 to at least assist in securing theinsert 18. In other embodiments, themagnet 44 may be positioned at any suitable location that will allow themagnet 44 to at least assist in securing theinsert 18 in themold 30. - In an embodiment where the
magnet 44 is an electromagnet, the electromagnet may be activated after the insert is loaded onto thesecond mold portion 34. The electromagnet may then at least assist in holding the insert in place until thefirst mold portion 32 engages thesecond mold portion 34, as shown inFIGS. 5-6 . Themagnet 44 may be removed from themold 30 before thematerial 60 is introduced into themold 30. The removal of themagnet 44 from themold 30 may be manual or automatic. In an embodiment where themagnet 44 is an electromagnet, themagnet 44 may be removed from thefirst mold portion 32 using theend magnet portion 45, for example by pulling themagnet 44 out of the first mold portion by pulling theend magnet portion 45. In the embodiments shown inFIGS. 5-6 , themagnet 44 has already been removed. In another embodiment (not shown) themagnet 44 may be positioned adjacent thefirst mold portion 32 orsecond mold portion 34 to hold theinsert 18 in place. - A compressive force may be applied to the
first mold portion 32 and thesecond mold portion 34, for example to push themold portions tabs 40 of theinsert 18 may be supported between thecutout portions 42 of thesecond mold portion 34 and lands 48 of thefirst mold portion 32. According to one embodiment, thematerial 60 is then introduced, for example injected, into thecavity 36 to form thepart 500. In one embodiment, thematerial 60 may be cast (charging) into the mold and around or immediately adjacent to at least a portion of the insert or a coating thereon. For exemplary embodiments, thematerial 60 may be one of cast iron, gray cast iron, aluminum, steel, titanium, stainless steel, any of a variety of other alloys, or metal matrix composite. Thematerial 60 may be molten. In another embodiment, thematerial 60 is a semi-solid material and may be introduced into thecavity 36 in accordance with the well known semi-solid forging process. In other embodiments, thematerial 60 may be introduced into themold 30 by any suitable method. In other embodiments, themold portions material 60, and thematerial 60 may enter the mold through the ingates (not shown). - In the embodiments shown in
FIGS. 3 and 5 , thematerial 60 may be introduced through afirst inlet 64 into afirst channel 62. Themagnet 44 may be removed from themold 30 before thematerial 60 is introduced through thefirst inlet 64 into thefirst channel 62. In one embodiment (not shown), thefirst channel 62 may extend through a portion of both thefirst mold portion 32 and thesecond mold portion 34. - Referring to
FIGS. 4 and 6 , in various embodiments thematerial 60 may be introduced through asecond inlet 66 into asecond channel 68 in thesecond mold portion 34. Themagnet 44 may be removed from themold 30 before thematerial 60 is introduced through thesecond inlet 66 into thesecond channel 68. In other embodiments, thematerial 60 may be introduced through any inlet located in a suitable place on themold 30. In one embodiment, thesecond channel 68 may extend through a portion of both thefirst mold portion 32 and thesecond mold portion 34. - Referring now to
FIGS. 7-8 , after thematerial 60 has cooled, thefirst mold portion 32 and thesecond mold portion 34 are separated and thefinished part 500 is removed from theopen mold 30. In one embodiment, thepart 500 is arotor assembly 12 and includes thehub portion 14, thefirst rotor cheek 16, and theinsert 18. Thepart 500 may then be further machined. For example, thetabs 40 may be machined off. When themold portions next insert 18 may be positioned in theopen mold 30 and the manufacturing process of thepart 500 may repeat. - Referring to
FIGS. 9-22 , one embodiment of the invention includes a product orpart 500 having a frictional damping means. The frictional damping means may be used in a variety of applications including, but not limited to, applications where it is desirable to reduce noise associated with a vibrating part or reduce the vibration amplitude and/or duration of a part that is struck, dynamically loaded, excited, or set in motion. In one embodiment the frictional damping means may include an interface boundary conducive to frictionally damping a vibrating part. In one embodiment the damping means may includefrictional surfaces 502 constructed and arranged to move relative to each other and in frictional contact, so that vibration of the part is dissipated by frictional damping due to the frictional movement of thesurfaces 502 against each other. - According to various illustrative embodiments of the invention, frictional damping may be achieved by the movement of the
frictional surfaces 502 against each other. The movement offrictional surfaces 502 against each other may include the movement of: surfaces of thebody 506 of the part against each other; a surface of thebody 506 of the part against a surface of theinsert 18; a surface of thebody 506 of the part against thelayer 520; a surface of theinsert 18 against thelayer 520; a surface of thebody 506 of the part against theparticles 514 or fibers; a surface of theinsert 18 against theparticles 514 or fibers; or by frictional movement of theparticles 514 or fibers against each other or against remaining binder material. - In embodiments wherein the
frictional surface 502 is provided as a surface of thebody 506 or theinsert 18 or alayer 520 over one of the same, thefrictional surface 502 may have a minimal area over which frictional contact may occur that may extend in a first direction a minimum distance of 0.1 mm and/or may extend in a second (generally traverse) direction a minimum distance of 0.1 mm. In one embodiment theinsert 18 may be an annular body and the area of frictional contact on africtional surface 502 may extend in an annular direction a distance ranging from about 20 mm to about 1000 mm and in a transverse direction ranging from about 10 mm to about 75 mm. Thefrictional surface 502 may be provided in a variety of embodiments, for example, as illustrated inFIGS. 9-22 . - Referring again to
FIG. 9 , in another embodiment of the invention one or more of theouter surfaces insert 18 orsurfaces body 506 of thepart 500 may include a relatively rough surface including a plurality ofpeaks 510 andvalleys 512 to enhance the frictional damping of the part. In one embodiment, the surface of theinsert 18 or thebody 506 may be abraded by sandblasting, glass bead blasting, water jet blasting, chemical etching, machining or the like. - Each
frictional surface 502 may have a plurality ofpeaks 510 and a plurality ofvalleys 512. The depth as indicated by line V of thevalleys 512 may vary with embodiments. In various embodiments, the average of the depth V of thevalleys 512 may range from about 1 μm-300 μm, 50 μm-260 μm, 100 μm-160 μm or variations of these ranges. However, for all cases there is local contact between the opposingfrictional surfaces 502 during component operation for frictional damping to occur. - In another embodiment of the invention the damping means or
frictional surface 502 may be provided byparticles 514 or fibers provided on at least one face of theinsert 18 or a surface of thebody 506 of thepart 500. Theparticles 514 may have an irregular shape (e.g., not smooth) to enhance frictional damping, as illustrated inFIG. 16 . One embodiment of the invention may include alayer 520 including theparticles 514 or fibers which may be bonded to each other or to a surface of thebody 506 of the part or a surface of theinsert 18 due to the inherent bonding properties of theparticles 514 or fibers. For example, the bonding properties of theparticles 514 or fibers may be such that theparticles 514 or fibers may bind to each other or to the surfaces of thebody 506 or theinsert 18 under compression. In another embodiment of the invention, theparticles 514 or the fibers may be treated to provide a coating thereon or to provide functional groups attached thereto to bind the particles together or attach the particles to at least one of a surface of thebody 506 or a surface of theinsert 18. In another embodiment of the invention, theparticles 514 or fibers may be embedded in at least one of thebody 506 of the part or theinsert 18 to provide the frictional surface 502 (FIGS. 11-12 ). - In embodiments wherein at least a potion of the
part 500 is manufactured such that theinsert 18 and/or theparticles 514 or fibers are exposed to the temperature of a molten material such as in casting, theinsert 18 and/orparticles 514 or fibers may be made from materials capable of resisting flow or resisting significant erosion during the manufacturing. For example, theinsert 18 and/or theparticles 514 or fibers may include refractory materials capable of resisting flow or that do not significantly erode at temperatures above 1100° F., above 2400° F., or above 2700° F. When molten material, such as metal, is cast around theinsert 18 and/or theparticles 514, theinsert 18 or theparticles 514 should not be wet by the molten material so that the molten material does not bond to theinsert 18 orlayer 520 at locations wherein africtional surface 502 for providing frictional damping is desired. - Illustrative examples of
suitable particles 514 or fibers include, but are not limited to, particles or fibers including silica, alumina, graphite with clay, silicon carbide, silicon nitride, cordierite (magnesium-iron-aluminum silicate), mullite (aluminum silicate), zirconia (zirconium oxide), phyllosilicates, or other high-temperature-resistant particles. In one embodiment of the invention theparticles 514 may have a length along the longest dimension thereof ranging from about 1 μm-350 μm, or 10 μm-250 μm. - In another embodiment of the invention, the
layer 520 may be a coating over thebody 506 of the part or theinsert 18. The coating may include a plurality ofparticles 514 which may be bonded to each other and/or to the surface of thebody 506 of the part or theinsert 18 by an inorganic or organic binder 516 (FIGS. 10 , 15) or other bonding materials. Illustrative examples of suitable binders include, but are not limited to, epoxy resins, phosphoric acid binding agents, calcium aluminates, sodium silicates, wood flour, or clays. In another embodiment of the invention theparticles 514 may be held together and/or adhered to thebody 506 or theinsert 18 by an inorganic binder. In one embodiment, the coating may be deposited on theinsert 18 orbody 506 as a liquid dispersed mixture of alumina-silicate-based, organically bonded refractory mix. - In another embodiment, the coating may include at least one of alumina or silica particles, mixed with a lignosulfonate binder, cristobalite (SiO2), quartz, or calcium lignosulfonate. The calcium lignosulfonate may serve as a binder. In one embodiment, the coating may include IronKote. In one embodiment, a liquid coating may be deposited on a portion of the insert and may include any high temperature ceramic coating, such as but not limited to, Ladle Kote 310B. In another embodiment, the coating may include at least one of clay, Al2O3, SiO2, a graphite and clay mixture, silicon carbide, silicon nitride, cordierite (magnesium-iron-aluminum silicate), mullite (aluminum silicate), zirconia (zirconium oxide), or phyllosilicates. In one embodiment, the coating may comprise a fiber such as ceramic or mineral fibers.
- When the
layer 520 includingparticles 514 or fibers is provided over theinsert 18 or thebody 506 of the part the thickness L (FIG. 10 ) of thelayer 520,particles 514 and/or fibers may vary. In various embodiments, the thickness L of thelayer 520,particles 514 and/or fibers may range from about 1 μm-400 μm, 10 μm-400 μm, 30 μm-300 μm, 30 μm-40 μm, 40 μm-100 μm, 100 μm-120 μm, 120 μm-200 μm, 200 μm-300 μm, 200 μm-250 μm, or variations of these ranges. - In yet another embodiment of the invention the
particles 514 or fibers may be temporarily held together and/or to the surface of theinsert 18 by a fully or partially sacrificial coating. The sacrificial coating may be consumed by molten metal or burnt off when metal is cast around or over theinsert 18. Theparticles 514 or fibers are left behind trapped between thebody 506 of the cast part and theinsert 18 to provide alayer 520 consisting of theparticles 514 or fibers or consisting essentially of theparticles 514 or fibers. - The
layer 520 may be provided over theentire insert 18 or only over a portion thereof. In one embodiment of the invention theinsert 18 may include a tab 534 (FIG. 10 ). For example, theinsert 18 may include an annular body portion and atab 534 extending radially inward or outward therefrom. In one embodiment of the invention at least onewettable surface 536 of thetab 534 does not include alayer 520 includingparticles 514 or fibers, or a wettable material such as graphite is provided over thetab 534, so that the cast metal is bonded to thewettable surface 536 to attach theinsert 18 to thebody 506 of thepart 500 but still allow for frictional damping over the remaining insert surface which is not bonded to the casting. - In one embodiment of the invention at least a portion of the
insert 18 is treated or the properties of theinsert 18 are such that molten metal will not wet or bond to that portion of theinsert 18 upon solidification of the molten metal. According to one embodiment of the invention at least one of thebody 506 of the part or theinsert 18 includes a metal, for example, but not limited to, a ferrous based material including, but not limited to, cast iron, gray cast iron, steel, or stainless steel, or a non-ferrous based material including, but not limited to, aluminum, magnesium, or titanium, or any of a variety of other alloys, or metal matrix composite including abrasive particles. In one embodiment of the invention theinsert 18 may include a material such as a metal having a higher melting point than the melting point of the molten material being cast around a portion thereof. - In one embodiment the
insert 18 may have a minimum average thickness of 0.2 mm and/or a minimum width of 0.1 mm and/or a minimum length of 0.1 mm. In another embodiment theinsert 18 may have a minimum average thickness of 0.2 mm and/or a minimum width of 2 mm and/or a minimum length of 5 mm. In other embodiments theinsert 18 may have a thickness ranging from about 0.1-20 mm, 0.1-6.0 mm, or 1.0-2.5 mm, or ranges therebetween. - Referring now to
FIGS. 13-14 , again thefrictional surface 502 may have a plurality ofpeaks 510 and a plurality ofvalleys 512. The depth as indicated by line V of thevalleys 512 may vary with embodiments. In various embodiments, the average of the depth V of thevalleys 512 may range from about 1 μm-300 μm, 50 μm-260 μm, 100 μm-160 μm or variations of these ranges. However, for all cases there is local contact between thebody 506 and theinsert 18 during component operation for frictional damping to occur. - In other embodiments of the invention improvements in the frictional damping may be achieved by adjusting the thickness (L, as shown in
FIG. 10 ) of thelayer 520, or by adjusting the relative position of opposedfrictional surfaces 502 or the average depth of thevalleys 512. - In one embodiment the
insert 18 is not pre-loaded or under pre-tension or held in place by tension. In one embodiment theinsert 18 is not a spring. Another embodiment of the invention includes a process of casting a material comprising a metal around aninsert 18 with the proviso that thefrictional surface 502 portion of the insert used to provide frictional damping is not captured and enclosed by a sand core that is placed in the casting mold. In various embodiments theinsert 18 or thelayer 520 includes at least onefrictional surface 502 or two opposite friction surfaces 502 that are completely enclosed by thebody 506 of the part. In another embodiment thelayer 520 including theparticles 514 or fibers that may be completely enclosed by thebody 506 of the part or completely enclosed by thebody 506 and theinsert 18, and wherein at least one of thebody 506 or theinsert 18 comprises a metal or consists essentially of a metal. In one embodiment of the invention thelayer 520 and/or insert 18 does not include or is not carbon paper or cloth. - Referring again to
FIGS. 9-10 , in various embodiments of the invention theinsert 18 may include afirst face 522 and an oppositesecond face 524 and thebody 506 of the part may include a firstinner face 526 adjacent thefirst face 522 of theinsert 18 constructed to be complementary thereto, for example nominally parallel thereto. Thebody 506 of the part includes a secondinner face 528 adjacent to thesecond face 524 of theinsert 18 constructed to be complementary thereto, for example parallel thereto. Thebody 506 may include a firstouter face 530 overlying thefirst face 522 of theinsert 18 constructed to be complementary thereto, for example parallel thereto. Thebody 506 may include a firstouter face 532 overlying thesecond face 524 of theinsert 18 constructed to be complementary thereto, for example parallel thereto. However, in other embodiments of the invention the outer faces 530, 532 of thebody 506 are not complementary to associated faces 522, 524 of theinsert 18. When the damping means is provided by a narrow slot-like feature 508 formed in thebody 506 of thepart 500, the slot-like feature 508 may be defined in part by a firstinner face 526 and a secondinner face 528 which may be constructed to be complementary to each other, for example parallel to each other. In other embodiments thesurfaces - Referring to
FIGS. 17-18 , in one embodiment of the invention theinsert 18 may be an inlay wherein afirst face 522 thereof is not enclosed by thebody 506 of the part. Theinsert 18 may include a tang ortab 534 which may be bent downward as shown inFIG. 17 . In one embodiment of the invention awettable surface 536 may be provided that does not include alayer 520 includingparticles 514 or fibers, or a wettable material such as graphite is provided over thetab 534, so that the cast metal is bonded to thewettable surface 536 to attach theinsert 18 to the body of the part but still allow for frictional damping on the non-bonded surfaces. Alayer 520 includingparticles 514 or fibers may underlie the portion of thesecond face 524 of theinsert 18 not used to make thebent tab 534. - In another embodiment the
insert 18 includes atab 534 which may be formed by machining a portion of thefirst face 522 of the insert 18 (FIG. 18 ). Thetab 534 may include awettable surface 536 having cast metal bonded thereto to attach theinsert 18 to the body of the part but still allow for friction damping by way of the non-bonded surfaces. Alayer 520 includingparticles 514 or fibers may underlie the entiresecond face 524 or a portion thereof. In other embodiments of the invention all surfaces including thetabs 534 may be non-wettable, for example by way of acoating 520 thereon, and features of thebody portion 506 such as, but not limited to, ashoulder 537 may be used to hold theinsert 18 in place. - Referring now to
FIG. 19 , one embodiment of the invention may include apart 500 having abody portion 506 and aninsert 18 enclosed by thebody part 506. Theinsert 18 may include through holes formed therein so that a stake or post 540 extends into or through theinsert 18. - Referring to
FIG. 20 , which is a sectional view ofFIG. 19 taken along line 20-20, in one embodiment of the invention alayer 520 including a plurality ofparticles 514 or fibers (not shown) may be provided over at least a portion of theinsert 18 to provide africtional surface 502 and to prevent bonding thereto by cast metal. Theinsert 18 including thelayer 520 may be placed in a casting mold and molten metal may be poured into the casting mold and solidified to form thepost 540 extending through theinsert 18. Aninner surface 542 defining the through hole of theinsert 18 may be free of thelayer 520 or may include a wettable material thereon so that thepost 540 is bonded to theinsert 18. Alternatively, in another embodiment thepost 18 may not be bonded theinsert 18 at theinner surface 542. Theinsert 18 may include a feature such as, but not limited to, ashoulder 505 and/or thepost 540 may include a feature such as, but not limited to, ashoulder 537 to hold the insert in place. - Referring now to
FIG. 21 , in another embodiment, the insert may be provided as an inlay in a casting including abody portion 506 and may include apost 540 extending into or through theinsert 18. Theinsert 18 may be bonded to thepost 540 to hold the insert in place and still allow for frictional damping. In one embodiment of the invention theinsert 18 may include a recess defined by aninner surface 542 of theinsert 18 and apost 540 may extend into theinsert 18 but not extend through theinsert 18. In one embodiment thepost 18 may not be bonded to theinsert 18 at theinner surface 542. Theinsert 18 may include a feature such as, but not limited to, ashoulder 505 and/or thepost 540 may include a feature such as, but not limited to, ashoulder 537 to hold the insert in place. - Referring now to
FIG. 22 , in another embodiment of the invention, aninsert 18 or substrate may be provided over anouter surface 530 of thebody portion 506. Alayer 520 may or may not be provided between theinsert 18 and theouter surface 530. Theinsert 18 may be constructed and arranged with through holes formed therethrough or through a recess therein so that cast metal may extend into or through theinsert 18 to form apost 540 to hold the insert in position and still allow for frictional damping. Thepost 540 may or may not be bonded to theinsert 18 as desired. Thepost 540 may extend through theinsert 18 and join another portion of thebody 506 if desired. - When the term “over,” “overlying,” overlies,” “under,” “underlying,” or “underlies” is used herein to describe the relative position of a first layer or component with respect to a second layer or component such shall mean the first layer or component is directly on and in direct contact with the second layer or component or that additional layers or components may be interposed between the first layer or component and the second layer or component.
- The above description of embodiments of the invention is merely exemplary in nature and, thus, variations thereof are not to be regarded as a departure from the spirit and scope of the invention.
Claims (28)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/165,729 US20090032211A1 (en) | 2007-08-03 | 2008-07-01 | Method for securing an insert in the manufacture of a damped part |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US95379307P | 2007-08-03 | 2007-08-03 | |
US12/165,729 US20090032211A1 (en) | 2007-08-03 | 2008-07-01 | Method for securing an insert in the manufacture of a damped part |
Publications (1)
Publication Number | Publication Date |
---|---|
US20090032211A1 true US20090032211A1 (en) | 2009-02-05 |
Family
ID=40337029
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/165,729 Abandoned US20090032211A1 (en) | 2007-08-03 | 2008-07-01 | Method for securing an insert in the manufacture of a damped part |
Country Status (1)
Country | Link |
---|---|
US (1) | US20090032211A1 (en) |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20120074618A1 (en) * | 2009-03-30 | 2012-03-29 | Saint-Gobain Glass France | Process for molding a plastic part with a metal insert held in place by magnetization, molding device and use of a method for fastening said insert |
US20130087299A1 (en) * | 2011-10-03 | 2013-04-11 | Warren G. Williamson | Methods of casting scroll compressor components |
US8904642B2 (en) | 2011-08-08 | 2014-12-09 | GM Global Technology Operations LLC | Manufacturing a vibration damped light metal alloy part |
US8968855B2 (en) | 2011-10-25 | 2015-03-03 | GM Global Technology Operations LLC | Method of forming a component having an insert |
US9016445B2 (en) | 2011-11-09 | 2015-04-28 | GM Global Technology Operations LLC | Light-weight and sound-damped brake rotor and method of manufacturing the same |
US9027718B2 (en) | 2011-08-31 | 2015-05-12 | GM Global Technology Operations LLC | Light-weight and sound-damped brake rotor and method of manufacturing the same |
US20160373154A1 (en) * | 2015-06-16 | 2016-12-22 | Ii-Vi Incorporated | Electronic Device Housing Utilizing A Metal Matrix Composite |
Citations (36)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US786938A (en) * | 1902-08-23 | 1905-04-11 | Leo J Fishel | Knitting-machine. |
US974024A (en) * | 1910-08-24 | 1910-10-25 | Charles B Carter | Metal-founding. |
US1484421A (en) * | 1924-02-19 | James s | ||
US2012838A (en) * | 1933-10-17 | 1935-08-27 | Sydney G Tilden | Noise-dampener for brake drums |
US2026878A (en) * | 1932-06-14 | 1936-01-07 | Budd Wheel Co | Method of making brake drums |
US2288438A (en) * | 1940-08-08 | 1942-06-30 | Dach Max | Brake drum |
US2978793A (en) * | 1958-04-16 | 1961-04-11 | Edward R Lamson | Method of lubricating anti-friction bearings |
US3127959A (en) * | 1962-03-12 | 1964-04-07 | Wengrowski Bronislaus | Cooling device for brake drums and shoes |
US3841448A (en) * | 1973-06-14 | 1974-10-15 | Budd Co | Reinforced brake drum |
US4195713A (en) * | 1974-05-29 | 1980-04-01 | Reduc Acoustics Ab | Sandwich structures with partial damping layers |
US4278153A (en) * | 1978-11-24 | 1981-07-14 | Goodyear Aerospace Corporation | Brake friction material with reinforcement material |
US4338758A (en) * | 1978-04-18 | 1982-07-13 | Reduc Acoustics Ab | Vibration damped structures and objects |
US4529079A (en) * | 1980-01-16 | 1985-07-16 | Borg-Warner Corporation | Cushion-bonded driven disc assembly and method of construction |
US5184662A (en) * | 1990-01-22 | 1993-02-09 | Quick Nathaniel R | Method for clad-coating ceramic particles |
US5965249A (en) * | 1997-08-07 | 1999-10-12 | Gore Enterprise Holdings, Inc. | Vibration damping composite material |
US6112865A (en) * | 1996-12-09 | 2000-09-05 | Chrysler Corporation | Damper for brake noise reduction (brake drums) |
US6231456B1 (en) * | 1999-04-05 | 2001-05-15 | Graham Rennie | Golf shaft vibration damper |
US6637497B2 (en) * | 2001-05-08 | 2003-10-28 | David J. Herron | Automotive and aerospace materials in a continuous, pressurized mold filling and casting machine |
US6648055B1 (en) * | 1999-04-16 | 2003-11-18 | Daimlerchrysler Ag | Casting tool and method of producing a component |
US6860315B2 (en) * | 2001-07-26 | 2005-03-01 | Copeland Corporation | Green sand casting method and apparatus |
US6945309B2 (en) * | 2003-07-18 | 2005-09-20 | Hayes Lemmerz International, Inc. | Method and apparatus for forming a part with dampener |
US7112749B2 (en) * | 2004-06-23 | 2006-09-26 | Sensata Technologies, Inc. | Sensor mounting apparatus for minimizing parasitic stress |
US7178795B2 (en) * | 2003-12-23 | 2007-02-20 | Basf Corporation | Mounting assembly for a vehicle suspension component |
US20070039710A1 (en) * | 2005-08-19 | 2007-02-22 | Newcomb Thomas P | Foundry mold assembly device and method |
US20070056815A1 (en) * | 2005-09-15 | 2007-03-15 | Hanna Michael D | Bi-metal disc brake rotor and method of manufacturing |
US20070062768A1 (en) * | 2005-09-19 | 2007-03-22 | Hanna Michael D | Bi-metal disc brake rotor and method of manufacturing |
US20070062664A1 (en) * | 2005-09-20 | 2007-03-22 | Schroth James G | Method of casting components with inserts for noise reduction |
US20070235270A1 (en) * | 2006-04-11 | 2007-10-11 | Thyssenkrupp-Waupaca Division | Insert for manufacture of an enhanced sound dampening composite rotor casting and method thereof |
US7293755B2 (en) * | 2004-11-04 | 2007-11-13 | Honda Motor Co., Ltd. | Vibration isolation device |
US20070298275A1 (en) * | 2006-06-27 | 2007-12-27 | Gm Global Technology Operations, Inc. | Damped automotive components with cast in place inserts and method of making same |
US20080099289A1 (en) * | 2006-10-30 | 2008-05-01 | Gm Global Technology Operations, Inc. | Coulomb damped disc brake rotor and method of manufacturing |
US20080185249A1 (en) * | 2004-10-08 | 2008-08-07 | Gm Global Technology Operations, Inc. | Damped products and methods of making and using the same |
US20090032569A1 (en) * | 2007-08-01 | 2009-02-05 | Gm Global Technology Operations, Inc. | Friction welding method and products made using the same |
US20090107787A1 (en) * | 2007-10-29 | 2009-04-30 | Gm Global Technology Operations, Inc. | Inserts with holes for damped products and methods of making and using the same |
US7594568B2 (en) * | 2005-11-30 | 2009-09-29 | Gm Global Technology Operations, Inc. | Rotor assembly and method |
US7604098B2 (en) * | 2005-08-01 | 2009-10-20 | Gm Global Technology Operations, Inc. | Coulomb friction damped disc brake caliper bracket |
-
2008
- 2008-07-01 US US12/165,729 patent/US20090032211A1/en not_active Abandoned
Patent Citations (38)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US1484421A (en) * | 1924-02-19 | James s | ||
US786938A (en) * | 1902-08-23 | 1905-04-11 | Leo J Fishel | Knitting-machine. |
US974024A (en) * | 1910-08-24 | 1910-10-25 | Charles B Carter | Metal-founding. |
US2026878A (en) * | 1932-06-14 | 1936-01-07 | Budd Wheel Co | Method of making brake drums |
US2012838A (en) * | 1933-10-17 | 1935-08-27 | Sydney G Tilden | Noise-dampener for brake drums |
US2288438A (en) * | 1940-08-08 | 1942-06-30 | Dach Max | Brake drum |
US2978793A (en) * | 1958-04-16 | 1961-04-11 | Edward R Lamson | Method of lubricating anti-friction bearings |
US3127959A (en) * | 1962-03-12 | 1964-04-07 | Wengrowski Bronislaus | Cooling device for brake drums and shoes |
US3841448A (en) * | 1973-06-14 | 1974-10-15 | Budd Co | Reinforced brake drum |
US4195713A (en) * | 1974-05-29 | 1980-04-01 | Reduc Acoustics Ab | Sandwich structures with partial damping layers |
US4338758A (en) * | 1978-04-18 | 1982-07-13 | Reduc Acoustics Ab | Vibration damped structures and objects |
US4278153A (en) * | 1978-11-24 | 1981-07-14 | Goodyear Aerospace Corporation | Brake friction material with reinforcement material |
US4529079A (en) * | 1980-01-16 | 1985-07-16 | Borg-Warner Corporation | Cushion-bonded driven disc assembly and method of construction |
US5184662A (en) * | 1990-01-22 | 1993-02-09 | Quick Nathaniel R | Method for clad-coating ceramic particles |
US6112865A (en) * | 1996-12-09 | 2000-09-05 | Chrysler Corporation | Damper for brake noise reduction (brake drums) |
US5965249A (en) * | 1997-08-07 | 1999-10-12 | Gore Enterprise Holdings, Inc. | Vibration damping composite material |
US6231456B1 (en) * | 1999-04-05 | 2001-05-15 | Graham Rennie | Golf shaft vibration damper |
US6648055B1 (en) * | 1999-04-16 | 2003-11-18 | Daimlerchrysler Ag | Casting tool and method of producing a component |
US6637497B2 (en) * | 2001-05-08 | 2003-10-28 | David J. Herron | Automotive and aerospace materials in a continuous, pressurized mold filling and casting machine |
US6860315B2 (en) * | 2001-07-26 | 2005-03-01 | Copeland Corporation | Green sand casting method and apparatus |
US6945309B2 (en) * | 2003-07-18 | 2005-09-20 | Hayes Lemmerz International, Inc. | Method and apparatus for forming a part with dampener |
US7178795B2 (en) * | 2003-12-23 | 2007-02-20 | Basf Corporation | Mounting assembly for a vehicle suspension component |
US7112749B2 (en) * | 2004-06-23 | 2006-09-26 | Sensata Technologies, Inc. | Sensor mounting apparatus for minimizing parasitic stress |
US20080185249A1 (en) * | 2004-10-08 | 2008-08-07 | Gm Global Technology Operations, Inc. | Damped products and methods of making and using the same |
US7293755B2 (en) * | 2004-11-04 | 2007-11-13 | Honda Motor Co., Ltd. | Vibration isolation device |
US7604098B2 (en) * | 2005-08-01 | 2009-10-20 | Gm Global Technology Operations, Inc. | Coulomb friction damped disc brake caliper bracket |
US20070039710A1 (en) * | 2005-08-19 | 2007-02-22 | Newcomb Thomas P | Foundry mold assembly device and method |
US20070056815A1 (en) * | 2005-09-15 | 2007-03-15 | Hanna Michael D | Bi-metal disc brake rotor and method of manufacturing |
US7775332B2 (en) * | 2005-09-15 | 2010-08-17 | Gm Global Technology Operations, Inc. | Bi-metal disc brake rotor and method of manufacturing |
US20070062768A1 (en) * | 2005-09-19 | 2007-03-22 | Hanna Michael D | Bi-metal disc brake rotor and method of manufacturing |
US20070062664A1 (en) * | 2005-09-20 | 2007-03-22 | Schroth James G | Method of casting components with inserts for noise reduction |
US7644750B2 (en) * | 2005-09-20 | 2010-01-12 | Gm Global Technology Operations, Inc. | Method of casting components with inserts for noise reduction |
US7594568B2 (en) * | 2005-11-30 | 2009-09-29 | Gm Global Technology Operations, Inc. | Rotor assembly and method |
US20070235270A1 (en) * | 2006-04-11 | 2007-10-11 | Thyssenkrupp-Waupaca Division | Insert for manufacture of an enhanced sound dampening composite rotor casting and method thereof |
US20070298275A1 (en) * | 2006-06-27 | 2007-12-27 | Gm Global Technology Operations, Inc. | Damped automotive components with cast in place inserts and method of making same |
US20080099289A1 (en) * | 2006-10-30 | 2008-05-01 | Gm Global Technology Operations, Inc. | Coulomb damped disc brake rotor and method of manufacturing |
US20090032569A1 (en) * | 2007-08-01 | 2009-02-05 | Gm Global Technology Operations, Inc. | Friction welding method and products made using the same |
US20090107787A1 (en) * | 2007-10-29 | 2009-04-30 | Gm Global Technology Operations, Inc. | Inserts with holes for damped products and methods of making and using the same |
Cited By (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20120074618A1 (en) * | 2009-03-30 | 2012-03-29 | Saint-Gobain Glass France | Process for molding a plastic part with a metal insert held in place by magnetization, molding device and use of a method for fastening said insert |
US9114556B2 (en) * | 2009-03-30 | 2015-08-25 | Saint-Gobain Glass France | Process for molding a plastic part with a metal insert held in place by magnetization and molding device |
US8904642B2 (en) | 2011-08-08 | 2014-12-09 | GM Global Technology Operations LLC | Manufacturing a vibration damped light metal alloy part |
US9027718B2 (en) | 2011-08-31 | 2015-05-12 | GM Global Technology Operations LLC | Light-weight and sound-damped brake rotor and method of manufacturing the same |
US20130087299A1 (en) * | 2011-10-03 | 2013-04-11 | Warren G. Williamson | Methods of casting scroll compressor components |
US8662144B2 (en) * | 2011-10-03 | 2014-03-04 | Emerson Climate Technologies, Inc. | Methods of casting scroll compressor components |
US8968855B2 (en) | 2011-10-25 | 2015-03-03 | GM Global Technology Operations LLC | Method of forming a component having an insert |
US9016445B2 (en) | 2011-11-09 | 2015-04-28 | GM Global Technology Operations LLC | Light-weight and sound-damped brake rotor and method of manufacturing the same |
US20160373154A1 (en) * | 2015-06-16 | 2016-12-22 | Ii-Vi Incorporated | Electronic Device Housing Utilizing A Metal Matrix Composite |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US7938378B2 (en) | Damped product with insert and method of making the same | |
US7836938B2 (en) | Insert with tabs and damped products and methods of making the same | |
US8028739B2 (en) | Inserts with holes for damped products and methods of making and using the same | |
US20090035598A1 (en) | Product with metallic foam and method of manufacturing the same | |
US8163399B2 (en) | Damped products and methods of making and using the same | |
US9409231B2 (en) | Method of casting damped part with insert | |
US7823763B2 (en) | Friction welding method and products made using the same | |
US20090020383A1 (en) | Damped part | |
US9527132B2 (en) | Damped part with insert | |
US20090032211A1 (en) | Method for securing an insert in the manufacture of a damped part | |
US9534651B2 (en) | Method of manufacturing a damped part | |
US8104162B2 (en) | Insert with filler to dampen vibrating components | |
US9500242B2 (en) | Component with inlay for damping vibrations | |
US9127734B2 (en) | Brake rotor with intermediate portion | |
CN102927186B (en) | Damped part | |
US20090260932A1 (en) | Chamber with filler material to dampen vibrating components | |
US8091609B2 (en) | Method of forming casting with frictional damping insert | |
US20100282550A1 (en) | Mode altering insert for vibration reduction in components |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: GM GLOBAL TECHNOLOGY OPERATIONS, INC., MICHIGAN Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:HANNA, MICHAEL D.;SUNDAR, MOHAN;REEL/FRAME:021564/0427;SIGNING DATES FROM 20080808 TO 20080811 |
|
AS | Assignment |
Owner name: UNITED STATES DEPARTMENT OF THE TREASURY, DISTRICT Free format text: SECURITY AGREEMENT;ASSIGNOR:GM GLOBAL TECHNOLOGY OPERATIONS, INC.;REEL/FRAME:022201/0448 Effective date: 20081231 Owner name: UNITED STATES DEPARTMENT OF THE TREASURY,DISTRICT Free format text: SECURITY AGREEMENT;ASSIGNOR:GM GLOBAL TECHNOLOGY OPERATIONS, INC.;REEL/FRAME:022201/0448 Effective date: 20081231 |
|
AS | Assignment |
Owner name: CITICORP USA, INC. AS AGENT FOR BANK PRIORITY SECU Free format text: SECURITY AGREEMENT;ASSIGNOR:GM GLOBAL TECHNOLOGY OPERATIONS, INC.;REEL/FRAME:022554/0538 Effective date: 20090409 Owner name: CITICORP USA, INC. AS AGENT FOR HEDGE PRIORITY SEC Free format text: SECURITY AGREEMENT;ASSIGNOR:GM GLOBAL TECHNOLOGY OPERATIONS, INC.;REEL/FRAME:022554/0538 Effective date: 20090409 |
|
AS | Assignment |
Owner name: GM GLOBAL TECHNOLOGY OPERATIONS, INC., MICHIGAN Free format text: RELEASE BY SECURED PARTY;ASSIGNOR:UNITED STATES DEPARTMENT OF THE TREASURY;REEL/FRAME:023126/0914 Effective date: 20090709 Owner name: GM GLOBAL TECHNOLOGY OPERATIONS, INC., MICHIGAN Free format text: RELEASE BY SECURED PARTY;ASSIGNORS:CITICORP USA, INC. AS AGENT FOR BANK PRIORITY SECURED PARTIES;CITICORP USA, INC. AS AGENT FOR HEDGE PRIORITY SECURED PARTIES;REEL/FRAME:023155/0769 Effective date: 20090814 Owner name: GM GLOBAL TECHNOLOGY OPERATIONS, INC.,MICHIGAN Free format text: RELEASE BY SECURED PARTY;ASSIGNOR:UNITED STATES DEPARTMENT OF THE TREASURY;REEL/FRAME:023126/0914 Effective date: 20090709 Owner name: GM GLOBAL TECHNOLOGY OPERATIONS, INC.,MICHIGAN Free format text: RELEASE BY SECURED PARTY;ASSIGNORS:CITICORP USA, INC. AS AGENT FOR BANK PRIORITY SECURED PARTIES;CITICORP USA, INC. AS AGENT FOR HEDGE PRIORITY SECURED PARTIES;REEL/FRAME:023155/0769 Effective date: 20090814 |
|
AS | Assignment |
Owner name: UNITED STATES DEPARTMENT OF THE TREASURY, DISTRICT Free format text: SECURITY AGREEMENT;ASSIGNOR:GM GLOBAL TECHNOLOGY OPERATIONS, INC.;REEL/FRAME:023156/0313 Effective date: 20090710 Owner name: UNITED STATES DEPARTMENT OF THE TREASURY,DISTRICT Free format text: SECURITY AGREEMENT;ASSIGNOR:GM GLOBAL TECHNOLOGY OPERATIONS, INC.;REEL/FRAME:023156/0313 Effective date: 20090710 |
|
AS | Assignment |
Owner name: UAW RETIREE MEDICAL BENEFITS TRUST, MICHIGAN Free format text: SECURITY AGREEMENT;ASSIGNOR:GM GLOBAL TECHNOLOGY OPERATIONS, INC.;REEL/FRAME:023162/0237 Effective date: 20090710 Owner name: UAW RETIREE MEDICAL BENEFITS TRUST,MICHIGAN Free format text: SECURITY AGREEMENT;ASSIGNOR:GM GLOBAL TECHNOLOGY OPERATIONS, INC.;REEL/FRAME:023162/0237 Effective date: 20090710 |
|
AS | Assignment |
Owner name: GM GLOBAL TECHNOLOGY OPERATIONS, INC., MICHIGAN Free format text: RELEASE BY SECURED PARTY;ASSIGNOR:UNITED STATES DEPARTMENT OF THE TREASURY;REEL/FRAME:025245/0909 Effective date: 20100420 |
|
AS | Assignment |
Owner name: GM GLOBAL TECHNOLOGY OPERATIONS, INC., MICHIGAN Free format text: RELEASE BY SECURED PARTY;ASSIGNOR:UAW RETIREE MEDICAL BENEFITS TRUST;REEL/FRAME:025315/0001 Effective date: 20101026 |
|
AS | Assignment |
Owner name: WILMINGTON TRUST COMPANY, DELAWARE Free format text: SECURITY AGREEMENT;ASSIGNOR:GM GLOBAL TECHNOLOGY OPERATIONS, INC.;REEL/FRAME:025324/0475 Effective date: 20101027 |
|
AS | Assignment |
Owner name: GM GLOBAL TECHNOLOGY OPERATIONS LLC, MICHIGAN Free format text: CHANGE OF NAME;ASSIGNOR:GM GLOBAL TECHNOLOGY OPERATIONS, INC.;REEL/FRAME:025781/0211 Effective date: 20101202 |
|
AS | Assignment |
Owner name: GM GLOBAL TECHNOLOGY OPERATIONS LLC, MICHIGAN Free format text: RELEASE BY SECURED PARTY;ASSIGNOR:WILMINGTON TRUST COMPANY;REEL/FRAME:034384/0758 Effective date: 20141017 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- AFTER EXAMINER'S ANSWER OR BOARD OF APPEALS DECISION |