Thermal fatigue and wear of compacted graphite iron brake discs with various thermomechanical properties

The increase in payload capacity of trucks has heightened the demand for cost-effective yet high performance brake discs.In this work,the thermal fatigue and wear of compacted graphite iron brake discs were investigated,aiming to provide an experimental foundation for achieving a balance between their thermal and mechanical properties.Compacted graphite iron brake discs with different tensile strengths,macrohardnesses,specific heat capacities and thermal diffusion coefficients were produced by changing the proportion and strength of ferrite.The peak temperature,pressure load and friction coefficient of compacted graphite iron brake discs were analyzed through inertia friction tests.The morphology of thermal cracks and 3D profiles of the worn surfaces were also discussed.It is found that the thermal fatigue of compacted graphite iron discs is determined by their thermal properties.A compacted graphite iron with the highest specific heat capacity and thermal diffusion coefficient exhibits optimal thermal fatigue resistance.Oxidization of the matrix at low temperatures significantly weakens the function of alloy strengthening in hindering the propagation of thermal cracks.Despite the reduced hardness,increasing the ferrite proportion can mitigate wear loss resulting from low disc temperatures and the absence of abrasive wear.

Numerical and Experimental Analysis of the Aerodynamic Torque for Axle-Mounted Train Brake Discs

As the velocity of a train increases,the corresponding air pumping power consumption of the brake discs increases proportionally.In the present experimental study,a standard axle-mounted brake disc with circumferential pillars was analyzed using a 1:1 scale model and a test rig in a wind tunnel.In particular,three upstream velocities were selected on the basis of earlier investigations of trains operating at 160,250,and 400 km/h,respectively.Moreover,3D steady computational fluid dynamics(CFD)simulations of the flow field were conducted to compare with the wind tunnel test outcomes.The results for a 3-car train at 180 km/h demonstrated:(1)good agreement between the air resistance torques obtained from the wind tunnel tests and the related numerical results,with differences ranging from 0.95%to 5.88%;(2)discrepancies ranging from 3.2 to 3.8 N·m;(3)cooling ribs contributing more than 60%of the air resistance torque;(4)the fast rotation of brake discs causing a significantly different flow field near the bogie area,resulting in 25 times more air pumping power loss than that obtained in the stationary brake-disc case.

Numerical Analysis of Braking Discs for a Taurus Class Locomotive

This paper shows the thermal and stress analysis of the worn brake disc for a Taurus class locomotive. The numerical analyses are carried out under the experimental testing program,Priifprogramm No.5,which is adjusted for this type of locomotives by UIC CODE 541-3.The simulations results under mentioned program show the most unfavorable case of braking.The numerical analysis is done with the finite element method(FEM), using ABAQUS software.

Simulation Analysis and Verifcation of Temperature and Stress of Wheel-Mounted Brake Disc of a High-Speed Train

During the braking process,a large amount of heat energy is generated at the friction surfaces between the brake disc and pads and rapidly dissipates into the disc volume.In this paper,a three-dimensional thermo-mechanical coupling model of high-speed wheel-mounted brake discs containing bolted joints and contact relationships is established.The direct coupling method is used to analyze the temperature and stress of the brake discs during an emergency braking event with an initial speed of 300 km/h.A full-scale bench test is also conducted to monitor the temperatures of the friction ring and bolted joints.The simulation result shows that the surface temperature of the friction ring reaches its peak value of 414°C after 102 s of braking,which agrees well with the bench test result.The maximum alternating thermal stress occurs in the bolt hole where the maximum circumferential compressive stress is−658 MPa and the maximum circumferential tensile stress is 134 MPa.During the braking process,the out-of-plane deformation of the middle part of the friction ring is larger than that of the edge,which increases the axial tensile load of the connecting bolt.This work provides support for the design of brake discs and connecting bolts.

Preparation and characteristics of C/C composite brake disc by multi-cylindrical chemical vapor deposition processes

The C/C composite brake discs were prepared by tri-cylindrical chemical vapor deposition （CVD） process. The optimum processing parameters were as follows： deposition temperature was 830 - 930 ℃, the gas- flow rates of N2 and propylene were 4.8 - 5.2 m^3/h and 5.8 - 6.2 m^3/h, respectively, the furnace pressure was 4.5 - 5.5 kPa and the deposition time was 200 h. The effects of processing parameters on the densified rates, thermal-physical property and mechanical performance of C/C composite brake discs were studied. The results show that density, heat conductivity, bend strength and abrasion ratio of the multi-cylindrica brake discs are 1. 02 - 1. 78 g/cm^3 , 31 W/（m·K）, 114 MPa and 7μm/s, respectively, which are approximately similar to those of the singlecylindrical ones. The gas tlow rate has no relation to the number of the cylinder and furnace loading. The utilization ratio of carbon can be improved by multi-cylinder CVD process without changing the characteristics of brake disc.

A DYNAMIC MODEL FOR A DISC EXCITED BY VERTICALLY MISALIGNED,ROTATING,FRICTIONAL SLIDERS

This paper presents a dynamic model for a disc subjected to two sliders rotating in the circumferential direction over the top and bottom surfaces of the disc.The two sliders are vertically misaligned and each is a mass-spring-damper system with friction between the slider and the disc. The moving loads produced by misaligned sliders can destabilise the whole system.Stability analysis is carried out in a simulated example.This model is meant to explain the friction mechanism for generating unstable vibration in many applications involving rotating discs.

Investigation into precision engineering design and development of the next-generation brake discs using Al/SiC metal matrix composites

Substantially lightweight brake discs with high wear resistance are highly desirable in the automotive industry.This paper presents an investigation of the precision-engineering design and development of automotive brake discs using nonhomogeneous Al/SiC metal-matrixcomposite materials.The design and development are based on modeling and analysis following stringent precision-engineering principles,i.e.,brake-disc systems that operate repeatably and stably over time as enabled by precision-engineering design.The design and development are further supported by tribological experimental testing and finite-element simulations.The results show the industrial feasibility of the innovative design approach and the application merits of using advanced metal-matrix-composite materials for next-generation automotive and electric vehicles.

A Review of a Study on Disc Brake Noise

With the development of the automotive industry, disc brake noise has become an issue of growing concern to the automotive industry and customers. In this paper, the types of disc brake noise have been discussed. After that, the theories and models that have been proposed as an explanation of brake squeal are reviewed. On the basis of these theories and models, some example simulations of disc brake squeal which use the Finite Element method and mathematical model have been introduced.

Gear walk instability caused by brake-disc friction characteristics

A multi-body dynamic rigid-flexible coupling model of landing gear is established to study the gear walk instability caused by the friction characteristics of the brake disc.After validating the model with the experimental results,the influence of the landing gear structure and braking system parameters on gear walk is further investigated.Among the above factors,the slope of the graph for the friction coefficient of the brake disc and the relative velocity of brake stators and rotors is the most influential factor on gear walk instability.Phase trajectory analysis verifies that gear walk occurs when the coupling of multiple factors causes the system to exhibit an equivalent negative damping trend.To consider a more realistic braking case,a back propagation neural network method is employed to describe the nonlinear behavior of the friction coefficient of the brake disc.With the realistic nonlinear model of the friction coefficient,the maximum error in predicting the braking torque is less than 10%and the effect of the brake disc temperature on gear walk is performed.The results reveal that a more negative friction slope may contribute to a more severe unstable gear walk,and reducing the braking pressure is an effective approach to avoid gear walk,which provides help for future braking system design.

Comprehensive modeling strategy for thermomechanical tribological behavior analysis of railway vehicle disc brake system

A comprehensive modeling strategy for studying the thermomechanical tribological behaviors is proposed in this work.The wear degradation considering the influence of temperature(T)is predicted by Archard wear model with the help of the UMESHMOTION subroutine and arbitrary Lagrangian–Eulerian(ALE)remeshing technique.Adopting the proposed method,the thermomechanical tribological behaviors of railway vehicle disc brake system composed of forged steel brake disc and Cu-based powder metallurgy(PM)friction block are studied systematically.The effectiveness of the proposed methodology is validated by experimental test on a self-designed scaled brake test bench from the perspectives of interface temperature,wear degradation,friction noise and vibration,and contact status evolution.This work can provide an effective way for the investigation of thermomechanical tribological behaviors in the engineering field.

Pin-on-disc tribological characterization of single ingredients used in a brake pad friction material

Researchers have long been studying the effects of the modification of friction material compositions on their tribological properties.Predictive models have also been developed,but they are of limited use in the design of new compositions.Therefore,this research aims to investigate the tribological behaviour of single ingredients in friction materials to develop a tribological dataset.This dataset could then be used as a foundation for a cellular automaton(CA)predictive model,intended to be a tool for designing friction materials.Tribological samples were almost entirely composed of four distinct friction material ingredients,and one sample composed of their mixture was successfully produced.Pin-on-disc(PoD)tribometer testing and scanning electron microscopy/energy-dispersive X-ray spectroscopy(SEM/EDXS)analysis were used for the tribological characterization.Each material showed distinct tribological properties and evolution of the contact surface features,and the synergistic effect of their mutual interaction was also demonstrated by their mixture.

Characterization of Automotive Brake Discs with Laser-Machined Surfaces

In the automotive and transport industry,braking noise and vibrations are persisting issues and difficult to control.Automo-tive engineers and researchers are putting considerable effort into overcoming these problems,and significant breakthroughs have been made in this area.In this study,M-shaped grooves were bionically designed and manufactured on the frictional surfaces of four automotive brake discs using a laser machine.Various tests were conducted to characterize the physical and mechanical performance of the modified discs along with their noise and vibration responses.The experimental results demonstrate that discs with laser-machined grooved surfaces have better surface hardness and residual stress reduction than discs with un-grooved surfaces.Significant improvement in the braking performance was observed in terms of disc thickness variation,friction and wear,noise,and vibration reduction.It is concluded that the reduction in braking noise and vibrations is mainly caused by the reduction in the coefficient of friction and wear,increase in damping ratio,and improvement of disc thickness variation of the brake disc by laser surface grooving.

Numerical Analysis of Railway Brake Disc

A certain number of railway brake discs made of gray cast iron,showed the presence of small cracks only after a few thousand kilometers.To investigate main causes of a brake disc failure,numerical analysis was done by using ABAQUS software.Numerical analysis resulted from a physical model of heat flux in dependence of braking time.Physical model was applied considering all demands and presumptions given by industry representatives.

A finite element analysis(FEA)approach to simulate the coefficient of friction of a brake system starting from material friction characterization

The coefficient of friction(COF)is one of the most important parameters to evaluate the performance of a brake system.To design proper brake systems,it is important to know the COF when estimating the brake force and resulting torque.It is challenging to simulate the COF since friction in disc brakes is a complex phenomenon that depends on several parameters such as sliding velocity,contact pressure,materials,and temperatures,etc.There is a lack of studies found in the literature focusing on simulation of the COF for a full brake system based on tribometer material characterization.The aim of this work is therefore to investigate the possibility to use a finite element analysis(FEA)approach combined with a COF pv-map to compute the global COF of a disc brake system.The local COF is determined from a pv-map for each local sliding velocity and contact pressure determined by the FEA.Knowing the local COF,the braking force of the entire brake system and the global COF can be evaluated.Results obtained by the simulation are compared with dyno bench test of the same brake system to investigate the validity of the simulation approach.Results show that the simulation is perfectly in line with the experimental measurements in terms of in-stop COF development,but slightly higher with a positive offset for every braking.