FEM numerical analysis of the compaction of a mixture of brake pad components taking account of the real shapes and dimensions of particles

Abstract

The aim of this paper is the numerical prediction of the behaviour of the powder used during the compaction of the compound of which brake pads are composed. The numerical simulations using the finite element method were carried out in the MSC.Marc 2014 program for the case of the compaction of a representative model of compacted material. Due to the cylindrical shape of the compacted material and the randomly determined distribution of powder particles in the compound, the assumption was made that one could simulate the 2D model with appropriate boundary conditions. The shape and size of the compound particles were determined using an optical microscope. The properties of the particles were considered as elastic-plastic. It was found that particles of flake graphite, zinc oxide and synthetic graphite are subjected to the greatest plastic deformation. The smallest values of deformation occur during the compacting of particles undergoing the work hardening phenomenon, i.e. steel and brass wools. The phenomenon of strain hardening affects the nature of particle interactions (particle distribution) and the value of the maximum equivalent plastic strains obtained for individual strengthening models. K e y w o r d s : brake pad, finite element method, powder compaction, numerical modelling