Brake Disc Design Research Articles

Heat transfer and flow analysis through a new brake disc design: a CFD approach

Heat transfer and flow analysis through a new brake disc design: a CFD approach

Design and Control of the Natural Frequency of Brake Discs in the Aspect of the Gray Cast Iron Production Process.

The results of research on the influence of the chemical composition of cast iron and its potential changes in the production cycle on the elastic properties and the correctness of numerical simulations of the natural frequency of ventilated brake discs are presented. The tests were carried out for three grades of gray cast iron with flake graphite with a eutectic saturation coefficient ranging from 0.88 to 1.01. A quantitative metallographic assessment of the pearlitic cast iron matrix and graphite precipitates was carried out, and the hardness and compressive/tensile strength of individual cast iron grades were determined, taking into account the limit contents of the alloying elements. Next, ultrasonic tests were performed, and the elastic properties of cast iron were determined. Based on the obtained data, a numerical modal analysis of brake discs was performed, the results of which were compared with the actual values of an FRF frequency analysis. The error of the computer simulations was estimated at approx. 1%, and it was found that the accuracy of the calculations of the first natural frequency did not depend on the dimensions (size) of the discs and the chemical composition of the cast iron from which they were cast. The functional relationships between the chemical composition of cast iron, its strength and elasticity and the first natural frequency of the disc vibrations were determined, and a database of the material parameters of the produced cast iron grades was developed. An implementation example showed the validation of the brake disc design with natural frequency prediction and demonstrated a high convergence of the experimental results with the simulated values. Using I-MR control cards, both the effectiveness of designing and predicting the natural vibrations of brake discs based on the implemented material database as well as the stability of the gray cast iron production and disc casting processes were confirmed.

A Numerical Study on the Thermal Behavior of Various Brake Disc Designs

The performance of a braking system is a fundamental requirement in both the railway and automotive vehicles. The brake disc is the main component of the braking system; it is considered one of the most critical parts for safety in modern vehicles. The braking performance and the vehicle safety are strongly dependent on the brake disc design ensuring the conversion of the kinetic energy of a moving vehicle into thermal energy dissipated in form of heat. In this work, a complete thermal analysis is proposed in order to identify the behavior of three different designs of brake discs under coupled mechanical and thermal loads. By simulating the condition of normal braking, the temperature distribution and variation are obtained using the numerical simulation for each brake disc. A comparison of simulation results is exposed to evaluate the effect of ventilation system design on the thermal behavior of the studied brake discs.

Modelling and analysis of ventilated disc Brakes using Creo and FEA software

Abstract: An important part of a car's safety system is the brakes. Brakes are easily worn, leading to unpredictable disasters. To avoid this, ventilated disc brakes are used, which helps the brakes to work well in stressful conditions and high temperatures. The materials used play an important role in determining performance. The main objective of this research work is to analyze the current design and conduct a suitable brake rotor analysis to improve its performance. Existing brake disc designs are modeled in Creo and analyzed with software. The material grades used in this study were performed on stainless steel, grey cast iron, structural steel, and titanium alloy brake discs using the same brake disc design to determine the best grade. Keywords: ventilated disc brake, creo, thermal analysis, static analysis.

A Heat Pipe Based Brake Disc Design and Numerical Simulation

A Heat Pipe Based Brake Disc Design and Numerical Simulation

Design and Thermal Behaviour of Brake Discs with Various Ceramics for Effective Heat Transfer

Design and Thermal Behaviour of Brake Discs with Various Ceramics for Effective Heat Transfer

Multi-objective and Robust Optimization Design of Brake Disc Based onResponse Surface Method

Multi-objective and Robust Optimization Design of Brake Disc Based onResponse Surface Method

Squeal analysis of thin-walled lattice brake disc structure

This paper presents a dynamic stability study of a novel brake disc design consisting of periodic lattice truss substructures. An integrated approach of theoretical modeling, experimental modal analysis, and finite elements methods is employed in this investigation to understand the squeal characteristics. The brake system is analytically modeled by a rotating annular disc subjected to in-plane frictional loads. Natural frequencies and forced response of the brake disc are obtained and validated by finite elements results. Experimental modal analysis of the lattice brake rotor/pad system with free-free boundary conditions is performed to obtain the modal properties of the brake rotor as inputs to the finite elements model. The FEA also includes models for the heat convection during braking and the non-linear contact forces between the rotor and the pads obtained from simulations of the SAE J2521 drag braking noise test matrix. The likelihood of squeal noise occurrence or squeal propensity for both the lattice and conventional vanned type brake discs are examined. The propensity is quantified by the standard deviation of the statistical occurrence of brake instability. It is shown that the lattice brake disc design has a lower propensity in the low frequency range of about 4 to 8kHz.

Homogenized modeling and micromechanics analysis of thin-walled lattice plate structures for brake discs

Periodic cellular structures, especially lattice designs, have potential to improve the cooling performance of brake disk system. In this paper, the method of two scales asymptotic homogenization was used to indicate the effective elastic stiffnesses of lattice plates structures. The arbitrary topology of lattice core cells connected to the back and front plates which are made of generally orthotropic materials, due to use in brake disc design. This starts with the derivation of general shell model with consideration of the set of unit cell problems and then making use of the model to determine the analytical equations and calculate the effective elastic properties of lattice plate concerning the connected back and front plates. The analytical and numerical method allows determining the stiffness properties and the internal forces in the trusses and plates of the lattice. Three types of core-based lattice plates, which are pyramidal, X-type and I-type lattices, have been studied. The I-type lattice is characterized here for the first time with particular attention on the role that the cell trusses and plates plays on the stiffness and strength properties. The lattice designs are finite element characterized and compared with the numerical and experimentally validated pyramidal and X-type lattices under identical conditions. The I-type lattice provides 4% higher strength more than the other lattice types with 9% higher truss fraction coefficient. Results show that the stiffness and yield strength of the lattices depend upon the stress–strain response of the parent alloy of trusses and plates, the truss mass fraction coefficient, the face carriers thickness and the core elements parameters. The study described here is limited to a linear analysis of lattice properties. Geometric nonlinearities, however, have a considerable impact on the effective behavior of a lattice and will be the subject of future studies.

Design, Manufacturing and Analysis of Alloy Steel Brake Disc

Each single system has been studied and developed in ordered to meet the safety requirement. Instead of having air bag, good suspension systems, good handling and safe cornering, there is one most critical system in the vehicle which is brake system. Without brake system in the vehicle will put a passenger in unsafe position. Therefore, it is must for all vehicles to have proper brake system. In this paper alloy steel disc brake material use for calculating normal force, shear force and piston force And also calculating the brake distance of disc brake. The standard disc brakes two wheelers model using in ANSYS and done the Thermal analysis and Model analysis also calculate the Heat flux and Temperature of disc brake model. This is important to understand action force and friction force on the disc brake new material, how disc brake works more efficiently, which can help to reduce the accident that may happen in each day.

Improvement in the brake disc design for heavy vehicles by parametric evaluation

Design of the brake disc geometry for a given brake disc material provides an opportunity for improvement in the fatigue life of the brake disc. High thermomechanical loads at braking lead to substantial local plastification and also induce tensile residual stresses in certain areas of the brake disc. This contributes to shortening of the fatigue life of the brake disc by possible initiation and growth of cracks. In the present paper, a simulation approach for evaluation of brake disc designs with respect to thermomechanical performance is developed and applied. Brake disc performance is analysed using commercial finite element software by employing a constitutive model for grey cast iron implemented in a Fortran subroutine. The thermal loading consists of consecutive severe braking cycles at a constant brake power and a constant speed, with cooling between the brake cycles. Based on a previous experimental study, three different assumptions are made regarding the spatial distribution of the thermal load at braking. A standard commercial brake disc made from grey cast iron having straight vanes is used as the reference case. Geometrical modifications are introduced in the ventilation arrangement using a design-of-experiments approach, studying both straight cooling vanes and different pillar layouts. A preliminary assessment of the fatigue life of the brake discs is carried out. The results indicate that the introduction of different pillar arrangements instead of straight vanes make it possible to decrease the mass of the brake disc by up to 13% or to increase the fatigue life of the brake disc by about 50%.

ANALISIS DE LA CANTIDAD DE FLUJO DE CALOR CIRCUNDANTE ENTRE LOS CANALES DE REFRIGERACIÓN EN TRES DISCOS DE FRENO AUTOVENTILADOS

Introduction: the objective of this study was to analyzethe behavior of the temperature, velocity and heat flowin the ventilation duct of three brake disc designs usingcomputational fluid dynamics (CFD). Methods: thedesign software SolidWorks was used for the analysis. Thethree disc designs differed in geometry and application.The numerical results for the flow of heat through theventilation channels were compared with mathematicallyobtained results. Results: the numerical results showedthat the discs performed well under severe operatingconditions (80 Km/h and an ambient temperature of22°C). It is very important in brake disc design to selectthe appropriate geometry, particularly the number andthe cross section of the ducts, and the type of material.Conclusions: numerical methods offer advantages forselecting the geometry and the material and for modelingthe fluid flow to optimize the heat dissipation to providethe maximum performance for properly maintainedcomponents.

Bionic Design and Stress Field Analysis of Brake Disc’s Surface Micro-Structure

The uneven friction of brake disk leads to the brake failure, which frequently results in serious traffic accidents. Based on the excellent wear-resisting properties of locust’s non-smooth surface structure, bionic brake disc with special surface micro-structure was designed. Utilizing ANSYS Workbench, the braking time and the stress distribution of both the bionic model and the smooth model during the whole process of brake under different initial velocity were analyzed. Compared to the smooth model, results showed that the braking time and contact stress decrease in a certain extent, indicating brake disc with special surface micro-structure exhibits relatively excellent braking performance and wear resistance. The results provided theories for exploring an optimization the method used to design brake discs with excellent braking performance and wear resistance.

Effect of Brake Pad Design On Friction and Wear with Hard Particle Present

Brake pad and disc design are important factors in ensuring excellent brake performance. But, particles from the environment can easily enter and interrupt the braking process and reduce braking performance. Friction depends on the design and surface properties of the pad and the disc. Wear happens in the brake system as the pad and disc try to withstand the braking force during the braking process. An experiment using brake dynamometer is done in order to determine the design effects on friction and wear when hard particle are present during the braking process. The test used three different brake pad designs under medium sliding load condition. It is found that Design 2 with a middle line groove provides better and stable brake torque and friction performance compared to Design 1 and Design 3. Design 2 also gavethe smallestweight loss inthe wear analysis of the pad.

The Thermo-Mechanical Coupling Analysis of Disc Brakes Transient Temperature Field

With the higher speed of the car, brake disc temperature will increase sharply when emergency braking, and its performance is demanded more and more higher. According to the Heat Conduction Theory, a brake disc's Thermo-mechanical Coupling model is built using ABAQUS software to analyze the brake disc transient temperature field. The analysis results shows that there is temperature gradient along the radial direction and axial direction, the temperature of the surface nodes with braking time has a wavy change, and the simulation result can be used as the references of brake disc design and selection.

Structural Modification of Disc Brake Judder Using Finite Element Analysis

Brake judder is a phenomenon of noise which its vibration can be felt physically by the driver of a vehicle. If this vibration is exposed to the driver for a long period it can lead to tiredness during driving. There are two types of judder which is cold judder and hot judder. This paper will be focusing on the hot judder. As a disc surface heats up during braking it causes both sides of the disc distort and hence produce a sinusoidal waviness around its edges. In this paper finite element analysis of hot judder is performed using a commercial software package, ABAQUS. An existing brake disc design is simulated and will be used as a baseline model. Various structural modifications made on the disc are proposed in an attempt to reduce brake judder in a disc brake assembly.

Combined Experimental and CFD Investigation of Brake Discs Aero-thermal Performances

The paper reports on a combined experimental and numerical investigation of the aero-thermal behavior of a vented automotive brake disc. The aim is to assess to which extent nowadays available CFD codes can be confidently used in the automotive brake disc design process. The reference experimental investigation provided the aero-thermal flow characteristics at the exit of a vented brake disc, with a pin type internal geometry and drilling holes. Tests were performed at one disc rotational speed and at several braking conditions. Star CD software was employed to compute the internal flow. Results were compared and discussed in terms of both global and local quantities. A general good agreement between numerical and experimental results was obtained. Thus CFD simulation was proved to be a very useful tool for brake disc designers.

Caractérisation thermomécanique de disques de frein ferroviaires multimatériaux

A new brake disc design is examined in order to improve high energy railway braking. The solution which consists to use friction materials able to endure hard thermomechanical conditions and to limit heat transfer toward the axle has been studied for multimaterial discs. The brake disc is composed of three distinct components : a stand disc, a thermal barrier flange and a friction flange. The insertion of a thermal barrier flange allows the use of aluminium alloy for the stand disc, reducing significantly the mass of the braking disc.Continuous braking simulations made on 1/4 reduced scale discs have allowed the study of the influence of thermal barrier position and thickness on disc and pad temperatures as well as on total mass disc. The friction material pair composed of an aluminium titanate pad and a Ni-Cr/Cr 3 C 2 cermet coated steel disc is very interesting as for friction coefficient stability and wear resistance. Endurance tests have shown that this system is able to damageless dissipate a 2 MJ energy per reduced disc side, which corresponds to 36 MJ for a disc on the scale 1. The studied friction material pair is also insensitive to humidity, a basic advantage in comparison with the common braking systems.

Design and Stress Analysis of No-Coning Brake Discs

During braking, the thermal gradient set up over the brake disc from the disc periphery down the bell to the mounting flange causes the disc to undergo undesirable distortions, termed ‘coning’. By proper design of the bell, this coning can be minimized, but, in so doing, there is a risk of high stresses occurring in the bell. In this paper, a numerical method of designing the bell to minimize coning and calculating the stresses in the bell is described. Comparison of results with standard analytical solutions shows that good agreement is obtained. An example of brake disc design and stress analysis by this method is given.