Effects of Braking Pressure Distribution on Temperature Field and Stress Field During Braking

2019 ◽  
Author(s):  
Xianyu Zeng ◽  
Yu Liu ◽  
Xiandong Liu ◽  
Yingchun Shan ◽  
Yue Zhang ◽  
...  
Keyword(s):  
Temperature Field ◽  
Fatigue Life ◽  
Stress Field ◽  
Pressure Distribution ◽  
Thermal Fatigue ◽  
Driving Safety ◽  
Brake Disc ◽  
Finite Element Software ◽  
Thermal Fatigue Life ◽  
Brake Discs

Abstract The braking performance of the vehicle directly affects the driving safety. Because of the different number of brake pistons and the wear of the brake pads, the distribution of braking pressure will be uneven, which will affect the distribution of temperature field and stress field during braking, then affect the thermal fatigue life of brake discs. Therefore, in this paper, the static tensile and compressive tests of gray cast iron HT200 samples cut from vehicle brake discs are carried out at −25°C, room temperature (25°C) and 500°C, and the stress-strain curves are analyzed to obtain mechanical properties such as strength limit, elastic modulus and so on at the temperature. Based on these parameters, the finite element software ABAQUS is used to simulate the single emergency braking condition. The thermal-structural coupling simulation of brake disc is carried out to study the influences of uneven brake pressure distribution on the temperature and stress fields of brake disc, which lays a foundation for the thermal fatigue life evaluation of brake disc.

scholarly journals Improvement in the brake disc design for heavy vehicles by parametric evaluation

2017 ◽  
Vol 231 (14) ◽  
pp. 1989-2004 ◽  
Author(s):  
Gaël Le Gigan
Keyword(s):  
Cast Iron ◽  
Fatigue Life ◽  
Thermal Loading ◽  
Grey Cast Iron ◽  
Brake Disc ◽  
Heavy Vehicles ◽  
Reference Case ◽  
Finite Element Software ◽  
Brake Discs ◽  
Grey Cast

Design of the brake disc geometry for a given brake disc material provides an opportunity for improvement in the fatigue life of the brake disc. High thermomechanical loads at braking lead to substantial local plastification and also induce tensile residual stresses in certain areas of the brake disc. This contributes to shortening of the fatigue life of the brake disc by possible initiation and growth of cracks. In the present paper, a simulation approach for evaluation of brake disc designs with respect to thermomechanical performance is developed and applied. Brake disc performance is analysed using commercial finite element software by employing a constitutive model for grey cast iron implemented in a Fortran subroutine. The thermal loading consists of consecutive severe braking cycles at a constant brake power and a constant speed, with cooling between the brake cycles. Based on a previous experimental study, three different assumptions are made regarding the spatial distribution of the thermal load at braking. A standard commercial brake disc made from grey cast iron having straight vanes is used as the reference case. Geometrical modifications are introduced in the ventilation arrangement using a design-of-experiments approach, studying both straight cooling vanes and different pillar layouts. A preliminary assessment of the fatigue life of the brake discs is carried out. The results indicate that the introduction of different pillar arrangements instead of straight vanes make it possible to decrease the mass of the brake disc by up to 13% or to increase the fatigue life of the brake disc by about 50%.

Numerical Modeling and Simulation Analysis of Temperature Field of Disc Brake on Trains

2011 ◽  
Vol 199-200 ◽  
pp. 1492-1495 ◽  
Author(s):  
Guo Shun Wang ◽  
Rong Fu ◽  
Liang Zhao
Keyword(s):  
Temperature Field ◽  
Temperature Gradient ◽  
High Speed ◽  
Large Scale ◽  
Working Condition ◽  
Constant Speed ◽  
Brake Disc ◽  
Disc Brake ◽  
Brake Pad ◽  
Finite Element Software

The simulation calculation on the temperature field of the disc brake system on high-speed trains under the working condition of constant speed at 50Km/h is made. A steady-state calculation model is established according to the actual geometric size of a brake disc and a brake pad, and the analog calculation and simulation on the temperature field of the brake disc and the brake pad by using the large-scale nonlinear finite element software ABAQUS are carried out. The distribution rules of the temperature field of the brake disc and the brake pad under the working condition of constant speed are made known. The surface temperature of the brake disc at friction radius is the highest, with a band distribution for temperature. There exists a temperature flex point in the direction of thickness, of which the thickness occupies 15% of that of the brake disc; due to the small volume of the brake pad, the temperature gradient of the whole brake pad is not sharp, and larger temperature gradient occurs only on the contact surface.

scholarly journals Prediction of Thermal Fatigue Life of Lead-Free BGA Solder Joints by Finite Element Analysis

2001 ◽  
Vol 42 (5) ◽  
pp. 809-813 ◽  
Author(s):  
Young-Eui Shin ◽  
Kyung-Woo Lee ◽  
Kyong-Ho Chang ◽  
Seung-Boo Jung ◽  
Jae Pil Jung
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Fatigue Life ◽  
Thermal Fatigue ◽  
Solder Joints ◽  
Lead Free ◽  
Element Analysis ◽  
Thermal Fatigue Life

Thermal Fatigue and Fracture Mechanics Analysis of Aluminium Alloy

2011 ◽  
Vol 201-203 ◽  
pp. 2476-2480
Author(s):  
Wen Xiao Zhang ◽  
Guo Dong Gao ◽  
Guang Yu Mu
Keyword(s):  
Aluminum Alloy ◽  
Fatigue Life ◽  
Fracture Mechanics ◽  
Thermal Fatigue ◽  
Low Carbon Steel ◽  
Strain Range ◽  
J Integral ◽  
Low Carbon ◽  
Thermal Fatigue Life ◽  
Energy Aspect

The in-phase and out-of-phase thermal fatigue of aluminum alloy were experimentally studied. The fatigue life was evaluated analytically by using the elastic-plastic fracture mechanics method (mainly J integral). The results of experiments and calculations showed that the life of out-of-phase fatigue was longer than that of in-phase fatigue within the same strain range. This is the same as the results of other materials such as medium and low carbon steel. On the other hand, the predicted life was consistent with experimental results. This suggests that J integral as a mechanics parameter for characterizing the thermal fatigue strength of aluminum alloy and the calculation method developed here is efficient. A parameter ΔW was proposed from energy aspect to characterize the capacity of crack propagation. The in-phase thermal fatigue life was the same as the out-of-phase thermal fatigue life for identical ΔW values.

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