The simulation of transient braking force effects for disc brake caliper bench test machine

Abstract

Abstract. This study analyses a disk braking caliper bench testing machine under braking conditions, to testify its structure characteristics. The analyzed objects include rotating axes and six counterweights. The first step is to use the design software SolidWorks to build axis and counterweights models. Next, the models are transferred to the finite element analysis software ABAQUS to add boundary conditions and to conduct dynamic stress analysis. The ABAQUS simulated test machine instantly applied braking stress under rotating speed 1,300 and 2,000 RPM conditions. The results showed the maximum stress located at axis and counterweight 1 was about 200 MPa under 1,300 RPM; it had little influence on the axis as compared with yielding stress. Under the rotation speed 2,000 RPM, the maximum stress was about 380MPa. The maximum stress is half of yielding stress. The dynamic stress area was transfer from counterweight 1 to long diameter counterweights. So the results showed this design is safty. These design parameters can use for design check and machine manufacturing.