Thermo-Structural Analysis of Brake Disc-Pad Assembly of an Automotive Braking System

Braking is a phenomenon of stabilizing a moving vehicle to rest by actuating the braking system. The available kinetic energy from the dynamic body is transformed into mechanical energy by the braking system which is further converted into thermal energy for its dissipation into the surroundings. During the process of braking, the frictional contact between the brake disc and brake pad creates enormous amount of heat elevating the temperature of the system to a higher level. The objective of this numerical study is to minimize the heat produced during the braking process. Three unique ventilated brake disc and two brake pad profiles were developed using PTC Creo modelling tool and were subjected to ANSYS workbench to evaluate its thermal and structural performance with a braking cycle time of 4.50 sec. Total deformation, equivalent stress, temperature distribution and total heal flux were assessed. Based on the study, ventilated disc 3 can be the possible design with either of the brake pad profiles for effective usage in the automotive braking system.

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A Computational Study on the Use of an Aluminium Metal Matrix Composite and Aramid as Alternative Brake Disc and Brake Pad Material

Journal of Engineering ◽

10.1155/2014/494697 ◽

2014 ◽

Vol 2014 ◽

pp. 1-6 ◽

Cited By ~ 2

Author(s):

Nosa Idusuyi ◽

Ijeoma Babajide ◽

Oluwaseun. K. Ajayi ◽

Temilola. T. Olugasa

Keyword(s):

Metal Matrix Composite ◽

Matrix Composite ◽

Thermal Behaviour ◽

Temperature Difference ◽

Metal Matrix ◽

Computational Study ◽

Brake Disc ◽

Brake Pad ◽

Braking Process ◽

Aluminium Metal

A computational model for the heat generation and dissipation in a disk brake during braking and the following release period has been formulated. The model simulates the braking action by investigating the thermal behaviour occurring on the disc and pad surfaces during this period. A comparative study was made between grey cast iron (GCI), asbestos, Aluminium metal matrix composite (AMC), and aramid as brake pad and disc materials. The braking process and following release period were simulated for four material combinations, GCI disc and Asbestos pad, GCI disc and Aramid pad, AMC disc and Asbestos pad, AMC disc and Aramid pad using COMSOL Multiphysics software. The results show similarity in thermal behaviour at the contact surface for the asbestos and aramid brake pad materials with a temperature difference of 1.8 K after 10 seconds. For the brake disc materials, the thermal behaviour was close, with the highest temperature difference being 9.6 K. The GCI had a peak temperature of 489 K at 1.2 seconds and AMC was 465.5 K but cooling to 406.4 K at 10 seconds, while the GCI was 394.7 K.

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Tribological and dynamical analysis of a brake pad with multiple blocks for a high-speed train

Proceedings of the Institution of Mechanical Engineers Part J Journal of Engineering Tribology ◽

10.1177/1350650119896456 ◽

2019 ◽

Vol 234 (11) ◽

pp. 1771-1788

Author(s):

YK Wu ◽

JL Mo ◽

B Tang ◽

JW Xu ◽

B Huang ◽

...

Keyword(s):

High Speed ◽

Wear Behavior ◽

Dynamical Analysis ◽

Brake Disc ◽

Brake Pad ◽

High Speed Train ◽

Brake Squeal ◽

Element Analysis ◽

Single Block ◽

Middle Ring

In this research, the tribological and dynamical characteristics of a brake pad with multiple blocks are investigated using experimental and numerical methods. A dynamometer with a multiblock brake pad configuration on a brake disc is developed and a series of drag-type tests are conducted to study the brake squeal and wear behavior of a high-speed train brake system. Finite element analysis is performed to derive physical explanations for the observed experimental phenomena. The experimental and numerical results show that the rotational speed and braking force have important influences on the brake squeal; the trends of the multiblock and single-block systems are different. In the multiblock brake pad, the different blocks exhibit significantly different magnitudes of contact stresses and vibration accelerations. The blocks located in the inner and outer rings have higher vibration acceleration amplitudes and stronger vibration energies than the blocks located in the middle ring.

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Study on Pressure Change Rate of the Automatic Pressure Regulating Valve in the Electronic-Controlled Pneumatic Braking System of Commercial Vehicle

Processes ◽

10.3390/pr9060938 ◽

2021 ◽

Vol 9 (6) ◽

pp. 938

Author(s):

Hanwei Bao ◽

Zaiyu Wang ◽

Zihao Liu ◽

Gangyan Li

Keyword(s):

Control Method ◽

Pressure Change ◽

Autonomous Driving ◽

Commercial Vehicles ◽

Change Rate ◽

Braking System ◽

Theoretical Support ◽

Automatic Pressure ◽

Braking Process ◽

Vehicle Dynamic Model

In contrast to the traditional pneumatic braking system, the electronic-controlled pneumatic braking system of commercial vehicles is a new system and can remedy the defects of the conventional braking system, such as long response time and low control accuracy. Additionally, it can adapt to the needs and development of autonomous driving. As the key pressure regulating component in electronic-controlled pneumatic braking system of commercial vehicles, automatic pressure regulating valves can quickly and accurately control the braking pressure in real time through an electronic control method. By aiming at improving driving comfort on the premise of ensuring braking security, this paper took the automatic pressure regulating valve as the research object and studied the pressure change rate during the braking process. First, the characteristics of the automatic pressure regulating valve and the concept of the pressure change rate were elaborated. Then, with the volume change of automatic pressure regulating valve in consideration, the mathematical model based on gas dynamics and the association model between pressure change rate and vehicle dynamic model was established in MATLAB/Simulink and analyzed. Next, through the experimental test of a sample product, the mathematical models have been verified. Finally, the key structure parameters affecting the pressure change rate of the automatic pressure regulating valve and the influence law have been identified; therefore, appropriate design advice and theoretical support have been provided to improve driving comfort.

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

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.199-200.1492 ◽

2011 ◽

Vol 199-200 ◽

pp. 1492-1495 ◽

Cited By ~ 1

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.

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Evaluation of 3-D Computational Model of Oscillating Water Column Converter with Constructal Design with Three Degrees of Freedom and Limited Chimney Height

Defect and Diffusion Forum ◽

10.4028/www.scientific.net/ddf.407.128 ◽

2021 ◽

Vol 407 ◽

pp. 128-137

Author(s):

Vinícius Bloss ◽

Camila Fernandes Cardozo ◽

Flávia Schwarz Franceschini Zinani ◽

Luiz Alberto Oliveira Rocha

Keyword(s):

Water Column ◽

Wave Energy ◽

Degrees Of Freedom ◽

Numerical Study ◽

Mechanical Energy ◽

Ocean Waves ◽

Response Surfaces ◽

Oscillating Water Column ◽

Promising Source ◽

Three Degrees Of Freedom

Theoretically, ocean waves contain enough mechanical energy to supply the entire world’s demand and, as of late, are seen as a promising source of renewable energy. To this end, several different technologies of Wave Energy Converters (WEC) have been developed such as Oscillating Water Column (OWC) devices. OWCs are characterized by a chamber in which water oscillates inside and out in a movement similar to that of a piston. This movement directs air to a chimney where a turbine is attached to convert mechanical energy. The analysis conducted was based on the Constructive Design Method, in which a numerical study was carried out to obtain the geometric configuration that maximized the conversion of wave energy into mechanical energy. Three degrees of freedom were used: the ratio of height to length of the hydropneumatic chamber (H1/L), the ratio of the height of the chimney to its diameter (H2/d) and the ratio of the width of the hydropneumatic chamber to the width of the wave tank (W/Z). A Design of Experiments (DoE) technique coupled with Central Composite Design (CCD) allowed the simulation of different combinations of degrees of freedom. This allowed the construction of Response Surfaces and correlations for the efficiency of the system depending on the degrees of freedom (width and height of the chamber), as well as the optimization of the system based on the Response Surfaces.

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Brake Wear Particle Size and Shape Analysis of Non-Asbestos Organic (NAO) and Semi Metallic Brake Pad

Jurnal Teknologi ◽

10.11113/jt.v71.3731 ◽

2014 ◽

Vol 71 (2) ◽

Author(s):

Hussain, S. ◽

M.K Abdul Hamid ◽

A.R Mat Lazim ◽

A.R. Abu Bakar

Keyword(s):

Particle Size ◽

Wear Particle ◽

Brake Disc ◽

Wear Particles ◽

Brake Pad ◽

Brake Pads ◽

Size And Shape ◽

Brake Wear Particles ◽

Brake Wear ◽

Particle Size And Shape

Brake wear particles resulting from friction between the brake pad and disc are common in brake system. In this work brake wear particles were analyzed based on the size and shape to investigate the effects of speed and load applied to the generation of brake wear particles. Scanning electron microscopy (SEM) with energy-dispersive X-ray spectroscopy (EDX) was used to identify the size, shape and element compositions of these particles. Two types of brake pads were studied which are non-asbestos organic and semi metallic brake pads. Results showed that the size and shape of the particles generatedvary significantly depending on the applied brake load, and less significantly on brake disc speed. The wear particle becomes bigger with increasing applied brake pressure. The wear particle size varies from 300 nm to 600 µm, and contained elements such as carbon, oxygen, magnesium, aluminum, sulfur and iron.

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The effects of grooved rubber blocks on stick–slip and wear behaviours

Proceedings of the Institution of Mechanical Engineers Part D Journal of Automobile Engineering ◽

10.1177/0954407018811039 ◽

2018 ◽

Vol 233 (11) ◽

pp. 2939-2954 ◽

Cited By ~ 1

Author(s):

Xiao Cui Wang ◽

Ji Liang Mo ◽

Huajiang Ouyang ◽

Xiao Dong Lu ◽

Bo Huang ◽

...

Keyword(s):

Relative Velocity ◽

Surface Modifications ◽

Experimental Results ◽

Brake Disc ◽

Experimental Setup ◽

Brake Pad ◽

Stick Slip ◽

Elastic Rubber ◽

Disc Configuration ◽

Rubber Block

This work presents an experimental and theoretical combined study of the effects of the elastic rubber blocks with different surface modifications on the friction-induced stick–slip oscillation and wear of a brake pad sample in sliding contact with an automobile brake disc. The experiments are conducted on the customized experimental setup in a pad-on-disc configuration. The experimental results show that (1) the friction system with the plain rubber block still exhibits visible stick–slip oscillation, but the intensity of the stick–slip oscillation is reduced to a certain degree compared with the Original friction system (without rubber block); (2) the grooved rubber blocks display a better ability to reduce the stick–slip oscillation compared with the plain rubber block; (3) the rubber blocks with a vertical groove (perpendicular to the relative velocity) or a horizontal groove (parallel to the relative velocity) or a diagonal groove (45° inclined to the relative velocity) on their surfaces can suppress the stick–slip oscillation more effectively with various degrees of success. The experimental results also reveal the varying effects of the different rubber blocks on wear. To explain the experimental phenomenon reasonably, a theoretical analysis is conducted to investigate the effects of different rubber blocks on both stick–slip oscillation and wear using ABAQUS. Furthermore, the analysis of the contact pressure on the pad interfaces and the deformation of the rubber blocks are studied to provide a possible explanation of the experimental results.

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EXPERIMENTAL AND NUMERICAL STUDY OF THERMAL ANALYSIS OF HIGH-SPEED FRICTION BRAKING SYSTEM

Journal of Advanced Manufacturing Systems ◽

10.1142/s0219686711002077 ◽

2011 ◽

Vol 10 (01) ◽

pp. 135-142

Author(s):

CHUNMEI ZHANG ◽

YONGFENG LI

Keyword(s):

Thermal Analysis ◽

Friction Surface ◽

High Speed ◽

Material Selection ◽

Numerical Study ◽

Friction Pair ◽

Maximum Temperature ◽

Dimensionless Time ◽

Braking System ◽

Friction Braking System

Thermal analysis can be used as one of the basis for the friction pair material selection in high-speed friction braking system. In this study, the experimental results showed that surface temperature could be reduced by increasing the radius of the friction disk or thermal conductivity coefficient of disk material with stable braking; In the early stage of long braking, the temperature on the friction surface rises rapidly, but further braking does not lead to a significant rise in temperature; In the case of short braking, there is not enough time for the friction surface to reach the critical temperature, and the disk surface reaches the maximum temperature at the end of braking. During long braking, the dimensionless time capacity of the friction surface reaching the highest temperature is F0 ≈ 0.1F0s.

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