Numerical optimisation and experimental validation of divided rail freight brake disc crown

In this study, numerical optimisation and experimental validation of a divided rail freight brake disc crown made of grey cast iron EN-GJL-250 is presented.The analysed brake disc is used in rail freight wagons and possesses a load capacity of 22.5 tons per axle. Two of the divided rail freight brake discs are mounted on each axle.With the aid of numerical analysis, the thermal dissipation properties of the brake disc were optimised and ventilation losses were reduced, and the numerical results were compared with experimental results. A one-way fluid–structure interaction analysis was performed. A computational fluid dynamic model of a divided rail freight brake disc, used to predict air flow properties and heat convection, was incorporated into a finite element model of the disc and used to evaluate the temperature of the disc. A numerical parametrical optimisation of cooling ribs of the brake disc was also performed, and novel optimised cooling ribs were developed. A transient thermal numerical analysis of the brake disc was validated using temperature measurements obtained during a braking test on a test bench. The ventilation losses of the brake disc were measured on a test bench specifically designed for the task, and the losses were compared to the simulation results. The experimentally obtained ventilation losses and temperature measurements compared favourably with the simulation results, confirming that this type of simulation process may be confidently applied in the future. Through systematic optimisation of the divided rail freight brake disc, ventilation losses were reduced by 37% and the mass was reduced by 21%, resulting in better thermal performance that will bring with it substantial energy savings.