Thermal stress analysis of disc brake using analytical and numerical methods

I T Jiregna,H G Lemu

doi:10.1088/1757-899x/1201/1/012033

Abstract

This article presents study of the thermal stress development in brake disc and the associated life cycle of the disc. The thermal stress analysis of disc brake under the first brake application and the influences of thermal loads on stress development of the disc have been investigated. The temperature distribution was conducted as a function of disc thickness and braking time. The study was done on the disc brake of Sports Utility Vehicle with a model of DD6470C. Partial solution approach was used to solve analytical temperature distribution through the thickness. The model was done using representative areas of the disc exposed to high temperature whose distribution result was obtained as a function of disc thickness and braking time. The solutions of coupled thermal transient fields and stress fields were obtained based on thermal-structural coupled analysis. Based on the model developed for the study, the positions of high and low stress formations were investigated, and it has been observed that thermal stress and temperature gradient show similar behavior through the thickness of disc. Generally, high temperature and stress components were found on the rubbing surfaces of the disc.

Highlights

The amount of accumulated kinetic energy in dynamic mechanical systems is converted into thermal energy at the interface of connecting parts according to the first law of thermodynamics [1]
A disc brake generates retardation force by converting kinetic energy into thermal energy out of which some amount of heat would be dissipated in the discs by conduction while some other amount is removed to the surrounding by convection or radiation process [4]
The temperature distribution was conducted as a function of disc thickness and braking time and the results obtained in both analytical and finite element method (FEM) are similar

Summary

Introduction

The amount of accumulated kinetic energy in dynamic mechanical systems is converted into thermal energy at the interface of connecting parts according to the first law of thermodynamics [1]. The disc brake, which is a type of friction brake, is a very critical part of the vehicle and exposed to a nonlinear and thermoelastic loading [2]. It is usually located on the front axle of vehicles and used to adjust or control the speed of vehicle according to the changing road and traffic conditions [3]. If heat dissipation occurs slowly, it will result in the rise of disc temperature and reduce the braking performance and may lead to surface crack propagation

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Discussion

Conclusion