Wear calculation and life prediction model of disc brake based on elastoplastic contact mechanics

Abstract

For the friction and wear of the braking surface of the disc brake, the mechanism of friction contact deformation of rough surface is analyzed. Considering elastoplastic contact mechanics of the friction surfaces, combined with Archard wear calculation theory, a wear calculation model of fractal rough surface is established, and a wear life prediction of the brake disc is proposed. Based on high-speed and heavy-load braking conditions, the influence of different braking parameters on the surface wear of brake disc is studied. Moreover, a pin-on-disc wear test is used to verify the validity of the wear calculation model, and the average relative error of test and simulation is 4.97%. The research results show that the fractal parameters affect the complexity of the rough surface, and surface wear is mainly caused by interface plastic contact. The friction coefficient is large, which can strengthen the surface shear effect. Large load and high speed would increase the real contact area of the surface and increase the wear volume per unit time. Furthermore, the wear life of the brake disc could be estimated, which is of great significance for raising the wear life of the brake disc, improving braking life and braking efficiency.