Patent ID: 8118079

Claim:
A method of casting a pair of like or identical brake rotors, each brake rotor including a central round hub with an axis of rotation and an integral radially extending annular rotor body, the hub extending axially with respect to the annular rotor body so that the brake rotor has a hub side and a rotor body side, and the annular rotor body of each brake rotor including an annular sound damping insert; the method comprising: providing complementary sand mold bodies with like casting cavities for defining surfaces of the hub sides of the pair of brake rotors, the casting cavities to be in face-to-face relationship for casting of the pair of brake rotors; providing at least two annular sound damping inserts, an annular splitter sand core and two like rib sand cores in an arrangement with one of the two like rib sand core on each side of the annular splitter sand core and with one of the two sound damping insert between each like rib sand core and the annular splitter sand core: the annular splitter sand core having two opposite sides, the annular splitter sand core comprising like casting surfaces on each side for supporting an annular sound damping insert on each casting surface and for shaping surfaces of the rotor body side of each brake rotor; the two like rib sand cores having front surfaces for defining surfaces of the rotor body side of each brake rotor, and back surfaces for engaging and enclosing the annular splitter sand core and for facing contact with each other; placing the assembly of cores and inserts between the complementary sand mold bodies to form a mold and core combination; and thereafter casting molten metal in the mold and core combination to form a pair of brake rotors with sound damping inserts.