Abstract
The operating conditions during the braking process in an automobile affect the tribological contact between the pad and disc brake, thus, influencing the times and distances of braking and, in a more significant way, the safety of the braking process. This mathematical work aimed to provide a general visualization of the disc brake’s mechanical, dynamic, and thermal behavior under different operating conditions through 2D maps of the power dissipated, braking time, and braking distance of a disc brake with a ventilation blade N- 38 type. However, the dissipated energy on the disc brake in terms of temperature was analyzed considering Newton’s cooling law and mathematical calculations through classical theories of the dynamic and mechanical behavior of the disc brakes. For this purpose, the Response Surface Methodology (RSM) and Distance Weighted Least Squares (DWLS) fitting model considered different operating conditions of the disc brake. The results demonstrate that the disc brakes can be used effectively in severe operational requirements with a speed of 100 km/h and an ambient temperature of 27 °C, without affecting the occupant’s safety or the braking system and the pad. For the different conditions evaluated, the instantaneous temperature reaches values of 182.48 and 82.94 °C, where the high value was found for a total deceleration to 100 km/h to 0, which represent a total braking distance of around 44.20 to 114.96 m depending on the inclination angle (θ). Furthermore, the energy dissipation in the disc brakes depends strongly on the disc, blades and pad geometry, the type of material, parameters, and the vehicle operating conditions, as can be verified with mathematical calculation to validate the contribution of the effectiveness of the braking process during its real operation.
Highlights
Disc brakes are fundamental elements to maintain maneuverability and, above all, safety in any vehicle, whether rotary or linear and that of its occupants
Mathematical calculations allowed corroboration of the behavior of the data obtained for the disc brake considered
2D maps of the braking time, distance, and power dissipation evidenced that the inclination angle provides a great variable to evaluate due to the difference in the behavior during the braking process, which, in many cases, affect the performance of the disc brake
Summary
Disc brakes are fundamental elements to maintain maneuverability and, above all, safety in any vehicle, whether rotary or linear and that of its occupants. There are currently different brake types, which are drum, band, disc, and conical. Disc brakes differ from other types in that the applied force is normal to the disc herd and not radial, as in drum and band brakes, the friction moment does not help the actuation moment (self-energizing effect), as occurs in drum and band brakes. This behavior allows slight changes in the friction coefficient not to affect the braking force required to stop the car [3,4]
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