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For the serious and uneven wear of the brake pad in the high-power disc brake during braking, the dynamic variation of the brake disc and the brake pad interface variable is considered, the wear calculation model is established based on the friction and wear mechanism, and the wear depth and volume of the brake pad can be calculated by equations. A finite element model of the brake disc and the brake pad is established by DEFORM software which can analyze wear of the brake pad directly. The variation trend of wear during braking is studied, and influences of braking load and initial braking speed on the wear are analyzed. The results show that the amount of the wear increases rapidly in the early wear stage of braking, and it becomes slow in the later stage; the wear of the brake pad is serious at the friction inlet and outlet, and the middle area of the brake pad is lightly worn; heavy braking load and high initial braking speed can exacerbate the wear of the brake pad.

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The fatigue failure mode of the brake disc is the initiation and expansion of the fatigue crack on the surface of the brake disc until the brake disc brakes. Therefore, considering the fatigue failure mode of the brake disc, the fatigue life of the brake disc is calculated. Firstly, the thermo-mechanical coupling model of the brake disc and pad is established by Abaqus software, so that temperature and stress of the brake disc could be obtained. Then, the surface crack initiation life of the brake disc is calculated by fe-safe software Finally, the fatigue crack growth life of the brake disc is calculated by nCode software. The calculation and analysis results show that the fatigue crack of the brake disc appears on the outer side of the brake disc friction surface under the working condition of this paper. The crack initiation life is that the number of braking is 12830 and the crack propagation life is 695000for the number of braking.