Thermomechanical Behavior of Brake Drums Under Extreme Braking Conditions

Braking efficiency is characterized by reduced braking time and distance,and therefore passenger safety depends on the design of the braking system.During the braking of a vehicle,the braking system must dissipate the kinetic energy by transforming it into heat energy.A too high temperature can lead to an almost total loss of braking efficiency.An excessive rise in brake temperature can also cause surface cracks extending to the outside edge of the drum friction surface.Heat transfer and temperature gradient,not to forget the vehicle’s travel environment(high speed,heavy load,and steeply sloping road conditions),must thus be the essential criteria for any brake system design.The aim of the present investigation is to analyze the thermal behavior of different brake drum designs during the single emergency braking of a heavy-duty vehicle on a steeply sloping road.The calculation of the temperature field is performed in transient mode using a three-dimensional finite element model assuming a constant coefficient of friction.In this study,the influence of geometrical brake drum configurations on the thermal behavior of brake drums with two different materials in grey cast iron FG200 and aluminum alloy 356.0 reinforced with silicon carbide(SiC)particles is analyzed under extreme vehicle braking conditions.The numerical simulation results obtained using FE software ANSYS are qualitatively compared with the results already published in the literature.

Effects of cooling rate on vermicular graphite percentage in a brake drum produced by onestep cored wire injection

In this research, a vermicular graphite cast iron brake drum was produced by cored wire injection in a one-step method. Silica sand and low-density alumina-silicate ceramic were used as molding materials in order to investigate the effect of cooling rate on percentage of vermicular graphite and mechanical properties of the brake drum casting. Several thermocouples were inserted into the casting in the desired positions to measure the temperature change. By means of one-step cored wire injection, the two residual concentrations of Mg and RE were effectively controlled in the ranges of 0.013%-0.017% and 0.019%-0.025%, respectively, which are crucial for the production of vermicular graphite cast iron and the formation of vermicular graphite. In addition, the cooling rate had a significant effect on the vermicular graphite percentage. In the case of the silica mold brake drum casting, there was an obvious difference in the cooling rate with the wall change, leading to a change in vermicular graphite percentage from 70.8% to 90%. In the low-density alumina-silicate ceramic mold casting, no obvious change in temperature was detected by the thermocouples and the percentage of the vermicular graphite was stable at 85%. Therefore, the vermicular graphite cast iron brake drum with a better combination of mechanical properties could be obtained.

Non-linear 2-DOF model and centre manifold theory to study limit cycle oscillations caused by drum-brake judder

This paper presents the research on the laws of systematic-parameter dependent variation in the vibration amplitude of drum-brake limit cycle oscillations (LCO). We established a two-degree non-linear dynamic model to describe the low-frequency vibration of the drum brake, applied the centre manifold theory to simplify the system, and obtained the LCO amplitude by calculating the normal form of the simplified system at the Hopf bifurcation point. It is indicated that when the friction coefficient is smaller than the friction coefficient at the bifurcation point, the amplitude decreases; whereas with a friction coefficient larger than the friction coefficient of bifurcation point, LCO occurs. The results suggest that it is applicable to suppress the LCO amplitude by changing systematic parameters, and thus improve the safety and ride comfort when applying brake. These findings can be applied to guiding the design of drum brakes.

Reliability Sensitivity Analysis for Drum Brake on Modal Stress

A reliability sensitivity analysis based on modal stress is presented and applied to predict the influence factors of parameters on drum brake.Firstly,the first 10 modes of prestress of the brake drum are performed in the software ANSYS Workbench.According to the results of brake noise research,it can be detected whether the drum brake meets the results that the noise frequency range of 500-1000 Hz.The reliability sensitivity design of mechanical parts based on the normal distribution parameters for complex mechanical system is discussed.Secondly,according to the first order second moment(FOSM)theory on reliability,the reliability sensitivity of drum brake is analyzed and calculated,and compared with the Monte Carlo(MC)numerical simulation results,The variation rules of reliability sensitivity is given,which provides a theoretical basis for the design of drum brake.

Estimation of automotive brake drum−shoe interface friction coefficient under varying conditions of longitudinal forces using Simulink

The suitable brake torque at the shoe-drum interface is the prerequisite of the active safety control.Estimation of accurate brake torque under varying conditions is predominantly the function of friction coefficient at the shoe-drum interface.The extracted friction coefficient has been used in the antilock braking system(ABS)algorithm to plot the μ-slip curve.The longitudinal forces like Coulomb friction force,contact force and actuating forces at the shoe ends are resolved under the equilibrium condition.The computation of the friction coefficient is presented for the symmetric and asymmetric length of the drum shoes to track the variations in the longitudinal forces.The classical mechanics formulae considering friction are simulated using virtual environment in Matlab/Simulink for the distribution of the Coulomb force.The dual air braking system set up operated at the 8 bar pressure is used to acquire data for the input parameters like distance of Coulomb friction force,distance of pivot point,and contact force applied.The evolved estimation algorithm extracted the maximum friction coefficient of 0.7 for the normal force arrangement of the contact force at the symmetric shoe length,while friction coefficient in the range of 0.3-0.7 is obtained at the asymmetric shoe length.