Abstract
A new approach to numerical simulation using the finite element method (FEM) for the rotational motion of discs for railway vehicle disc brake systems was proposed. For this purpose, spatial models of transient heating due to the friction of such systems with solid and ventilated discs were developed. The performed calculations and the results obtained allowed justification of the possibility of simplifying the shape of the ventilated brake disc through elimination of ventilation channels. This contributes to a significant reduction in computational time, without compromising the accuracy of the results. The spatial and temporal temperature distributions in the ventilated and the solid disc of the same mass were analyzed. The share of energy dissipated due to convection and thermal radiation to the environment in relation to the total work done during a single braking was investigated. The maximum temperature values found as a result of computer simulations were consistent with the corresponding experimental results.
Highlights
Carrying out a computer simulation with the use of FEA of the transient temperature field of the brake consists of several steps
The friction is perfect, i.e., the temperature in the contact area is the same, and the sum of the heat flux densities directed normally from the friction surface to the inside of each element is equal to the friction power density; The cooling of the free surfaces of the pads and the disc proceeds due to convection and thermal radiation to the surrounding air; where n o
For comparative in one of Twothe calculation models of the disc ventilated disc temperature werethe developed, differmodels, shape of the ventilated was simplified by replacing pillars with ing in their taking into account its rotational motion
Summary
Carrying out a computer simulation with the use of FEA of the transient temperature field of the brake consists of several steps. In the developed contact thermo-structural coupled computational model, the stopping time as well as the exponential increase in contact pressure and the nonlinear velocity change were known a priori before the analysis This includes the variable heat transfer coefficient from the surfaces of the pads and the disc. One of the most important requirements when developing such models, apart from the accurate determination of the maximum temperature and flash temperature occurring in the real contact areas of the pads with the disc, the variability of friction coefficients and wear intensity, etc., was to shorten the computational time. A comparative analysis of the temperature mode of the ventilated and solid discs of a rail vehicle was carried out, considering a single brake application For this purpose, two techniques for modeling the rotational motion of the disc or the displacement of the pad relative to a fixed disc are proposed. The calculated temperature values are shown to be consistent with the corresponding thermocouple measurement data
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