Modeling and simulation of frictional disc/pad interface considering the effects of thermo-mechanical coupling

Abstract

Purpose This study aims to investigate numerically a thermomechanical behavior of disc brake using ANSYS 11.0 which applies the finite element method (FEM) to solve the transient thermal analysis and the static structural sequentially with the coupled method. Computational fluid dynamics analysis will help the authors in the calculation of the values of the heat transfer (h) that will be exploited in the transient evolution of the brake disc temperatures. Finally, the model resolution allows the authors to visualize other important results of this research such as the deformations and the Von Mises stress on the disc, as well as the contact pressure of the brake pads. Design/methodology/approach A transient finite element analysis (FEA) model was developed to calculate the temperature distribution of the brake rotor with respect to time. A steady-state CFD model was created to obtain convective heat transfer coefficients (HTC) that were used in the FE model. Because HTCs are dependent on temperature, it was necessary to couple the CFD and FEA solutions. A comparison was made between the temperature of full and ventilated brake disc showing the importance of cooling mode in the design of automobile discs. Findings These results are quite in good agreement with those found in reality in the brake discs in service and those that may be encountered before in literature research investigations of which these will be very useful for engineers and in the design field in the vehicle brake system industry. These are then compared to experimental results obtained from literatures that measured ventilated discs surface temperatures to validate the accuracy of the results from this simulation model. Originality/value The novelty of the work is the application of the FEM to solve the thermomechanical problem in which the results of this analysis are in accordance with the realized and in the current life of the braking phenomenon and in the brake discs in service thus with the thermal gradients and the phenomena of damage observed on used discs brake.

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Study of friction, wear and plastic deformation of automotive brake disc subjected to thermo-mechanical fatigue

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