Abstract: A method of making a wheel end to be installed on a vehicle includes assembling a rotor and components with bearing surfaces to define an assembled module configured to be mounted to the vehicle, and preloading the bearing surfaces of the assembled module in a set amount as required for mounting the assembled module to the vehicle. The method further includes mounting the assembled module on a holding fixture and rotating the assembled module on the holding fixture. The method further includes, while rotating the preloaded assembled module, machining the face of the hub flange prior to affixing a rotor to the flange, and then machining a final cut on the rotor once the rotor is affixed to the flange. After machining, the assembled module remains preloaded with the set amount of preload as the assembled module is installed on the vehicle, thereby providing reduced lateral runout.

Abstract: A method of making a wheel end to be installed on a vehicle includes assembling a rotor and components with bearing surfaces to define an assembled module configured to be mounted to the vehicle, and preloading the bearing surfaces of the assembled module in a set amount as required for mounting the assembled module to the vehicle. The method further includes mounting the assembled module on a holding fixture and rotating the assembled module on the holding fixture. The method further includes, while rotating the preloaded assembled module machining the face of the hub flange prior to affixing a rotor to the flange, and then machining a final cut on the rotor once the rotor is affixed to the flange. After machining, the assembled module remains preloaded with the set amount of preload as the assembled module is installed on the vehicle, thereby providing reduced lateral runout.

Abstract: This invention relates to an improved apparatus and method for finish machining brake components. The apparatus includes an electrode ring adapted to be secured to a rotatable shaft. The electrode ring includes at least one plurality of circumferentially spaced apart electrodes adapted to be electrically connected to a power supply. Each one of the at least one plurality of electrodes are arranged adjacent each other around the circumference of the electrode ring. The apparatus further includes a positioning mechanism for positioning a rotating, electrically grounded rotor adjacent the electrode ring until sparks are formed between the electrode ring and the rotor. The sparks vaporize a portion of the rotor surface thereby creating a finished surface on the rotor having the desired dimensions.

Abstract: This invention relates to an improved apparatus and method for finish machining brake components. The apparatus includes an electrode ring adapted to be secured to a rotatable shaft. The electrode ring includes at least one plurality of circumferentially spaced apart electrodes adapted to be electrically connected to a power supply. Each one of the at least one plurality of electrodes are arranged adjacent each other around the circumference of the electrode ring. The apparatus further includes a positioning mechanism for positioning a rotating, electrically grounded rotor adjacent the electrode ring until sparks are formed between the electrode ring and the rotor. The sparks vaporize a portion of the rotor surface thereby creating a finished surface on the rotor having the desired dimensions.

Abstract: A brake disc assembly including an inner hub (14) extending between a drive end (16) and a wheel end (18) and a disc flange (20) extending radially about the circumference of the inner hub (14) at the wheel end (18) with the inner hub (14) having a bore (22) extending between the ends for receiving a drive shaft. A brake disc has a base (26) attached to the disc flange (20) about the circumference of the inner hub (14) and a rotor (28) extends radially from the base (26) and presents parallel braking surfaces (30). A bearing assembly surrounds the hub (14) between the drive end (16) and the disc flange (20) for supporting the hub (14) with an outer race (32) presents a support flange (34) for attachment to a support structure (36) and an inner race member (58) is disposed about the drive end (16).

Abstract: A method and apparatus for preventing lateral movement of a movable brake member of a brake assembly when in engagement with a rotatable brake member having a braking surface. The method includes creating a plurality of grooves in the braking surface. Each groove is parallel to adjacent grooves so that peaks are formed on a movable brake member which mirror the plurality of grooves. The peaks track within the grooves to prevent lateral movement of the movable brake member with respect to the braking surface. The apparatus includes a brake resurfacer for resurfacing a braking surface of a vehicle brake assembly while the braking surface is mounted to a vehicle. The resurfacer includes a substrate figured for mounting in the brake assembly in place of a movable brake member. The substrate supports cutting teeth, tines or an abrasive for removing braking surface material to resurface the braking surface.

Abstract: A method for fabricating a brake disc assembly comprising the steps of inserting a fixture post (72) through a bore (22) in the hub (14) and disposing a nose-shaped pressure plate (74) into a pocket (73) within the circumference of the inner hub (14) with a washer/nut (78) over the pressure plate (74) to place the post (72) in tension against the bearing assembly to maintain a pre-load on the bearing assembly. The outer race (32) of the bearing assembly is clamped with the gage surface (54) drawn against a gage (84) to properly orient the outer race (32) about a fixed axis (A). A spoke or disc (77) extends radially from the pressure plate (74) and is disposed in axially spaced relationship to the base (26) of the brake disc to be in circumferential driving relationship with the studs (64).

Abstract: A method and apparatus for preventing lateral movement of a movable brake member of a brake assembly when in engagement with a rotatable brake member having a braking surface. The method includes creating a plurality of grooves in the braking surface. Each groove is parallel to adjacent grooves so that peaks are formed on a movable brake member which mirror the plurality of grooves. The peaks track within the grooves to prevent lateral movement of the movable brake member with respect to the braking surface. The apparatus includes a brake resurfacer for resurfacing a braking surface of a vehicle brake assembly while the braking surface is mounted to a vehicle. The resurfacer includes a substrate figured for mounting in the brake assembly in place of a movable brake member. The substrate supports cutting teeth, tines or an abrasive for removing braking surface material to resurface the braking surface.

Abstract: A method of shaping a friction facing or lining is disclosed. A lining blank is positioned on a core member and a template having the desired groove patterns and periphery is mounted on the blank. Particles are directed against the template and the blank to form the lining grooves and peripheries. The particles also remove hanging fibers. In another embodiment, a template is placed over a friction facing or lining which has grooves formed by other methods. The particles remove any undesired material or hanging fibers from either the grooves or periphery or both.

Abstract: An apparatus for grinding a disc brake disc having opposite surfaces, the apparatus comprising: a free-standing support; a pair of rotors, at least one of which is a grinding rotor, the rotors attached to the support to extend in spaced relation at opposite sides of a disc for grinding at least one face of the disc, wherein at least one rotor is pivotally attached to the support and can be moved toward and away from the disc independent of the other rotors; adjustment means attached to the support to allow adjustment of the angle of at least one rotor in relation to a face of the disc; and drive means to rotate at least one of the rotors.

Abstract: A method of producing a rotatable brake component and bearing assembly is disclosed wherein the brake friction surface of the brake component is oriented in a predetermined relationship relative to an inner race of a bearing unit. In accordance with this method, a rotatable brake component (e.g., a rotor or drum) defining an axis and including a brake friction surface and a hub portion having a cylindrical bore formed therein is provided. Next, the bore of the hub is machined. A bearing unit is then installed in the bore of the hub portion. The bearing unit includes an outer race which engages the bore and an inner race rotatably supported relative thereto. The brake component and bearing assembly is then supported on a machining apparatus by the inner race of the bearing unit. Using the machining apparatus, the brake friction surface is machined whereby the brake friction surface is oriented in a predetermined relationship relative to the inner race of the bearing unit.