Abstract
Transient heat transfer analysis of disc brake has been performed to find out an ideal shape of pad geometry. The analysis has taken frictional heat between brake disc and pads as heat flux onto the friction surface, the disc and the pad's temperature fields then were explored involving thermal conduction, forced convection and surface radiation effects. The disc thermal expansion stress was then acquired by quasi-static analysis using its temperature of aforesaid heat transfer analysis. Five prototypes of pad designs with geometry and volume variations were implemented for analytical comparison. Both pads and disc are required to have lower and uniform temperature field and thermal stress. The results uncover that heat conduction is domination in heat dissipation progress during braking, and big volume pad is cooler. Pad volume has more impact to heat transfer procedure and temperature gradient than pad geometry variation does. The design has 10 triangle pads is considered to be an ideal candidate. Its maximum disc temperature and thermal stress are the least among the five designs.
Highlights
Started from the Japanese Shinkansen in 1964, highspeed train was reported to run fast and faster in commercial services
The temperature field is acquired by transient heat transfer analysis
Heat generation and partition at friction interface, thermal contact resistance, conduction, convection and radiation cooling, thermal deformations and stresses, and related failure mechanisms were deeply discussed for brakes with solid or ventilated disc
Summary
Started from the Japanese Shinkansen in 1964, highspeed train was reported to run fast and faster in commercial services. Disc brakes must dissipate large amounts of heat energy at high rates. Phenomena such as thermal banding [1], hotspotting [2] and thermal cracking [3] are thought to be main reasons cause disc failure. These premature failures relate to most critical brake design parameters, such as the braking energy, heat partition, friction coefficient, geometries and dimensions of the brake components, materials of the disc and the pad, even the contact pressure distribution [4]. The temperature field is acquired by transient heat transfer analysis
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