盘式制动器支架疲劳分析及优化

Fatigue Analysis and Optimization of the Disc Brake Bracket

取盘式制动器摩擦块的标准试样进行压缩试验,建立制动盘-摩擦块制动过程的数值模型,根据计算结果分析支架受力分配,并利用疲劳台架试验对数值模型进行验证;基于支架应力测试试验,建立支架有限元分析数值模型,研究盘式制动器支架的应力应变分布规律,结果表明:支架应力最大值出现在较细拱桥一侧,大于屈服强度,数值解与试验值吻合程度较好,说明模型可靠;基于20万次疲劳台架试验,建立盘式制动器的疲劳分析模型,研究盘式制动器支架疲劳寿命的影响因素;结合有限元分析和疲劳分析的结果,对盘式制动器支架进行形状优化,优化后支架应力得到明显改善,解决了目前盘式制动器支架易出现疲劳破坏的关键性问题。

Compression test was implemented on standard samples of disc brake friction pad. A numerical model of the brake process between disc brake and friction pad was established.Stress distribution of the bracketwas analyzed according to the numerical result. The numerical model was verifiedby the fatigue bench test. Based on the bracket stress test, a finite numerical model of bracket was carried outto obtain stress and strain distributions. Results show that the maximum stress of bracket appearedon the one side of thethin archand greater than the yield strength. The numerical solutions agreed well with the experimental values so that the model was reliable.Based on the 200000 times fatigue bench test, fatigue analysis model was established tastudyinfluencing factors on the fatigue life of the disc brake bracket. Combined withresults of the finite element analysis andthe fatigue analysis, shape optimization of thebracket was establishedtoimprove the bracket stress distribution, which solved the key problem that disc brake brackets areprone to fatigue failure.