Thermal and stress-strain state of friction pairs in ventilated disc brakes of lightweight vehicles
Keywords:friction, brake disc, brake pads, thermal load, stress-strain state, heat flow, von Mises stress, contact pressure, thermal expansion
The work is dedicated to the thermal behavior and stress-strain state of ventilated disc brakes installed in the lightweight vehicles (scooters, electric bikes, ATVs, etc.) using ANSYS environment in various experiment modes. Modeling of the temperature distribution in the rotor (disc) and the corresponding brake pads is determined taking into account a number of factors and input parameters during the braking operation: the amount of rotation speed, the gap between the pads and the disc, the speed of load application, thermal expansion, etc. Numerical modeling of the transient thermal and the stress fields in the area of contact between the pads and the rotor is carried out by the method of sequential thermostructural connection of the intermediate calculation states of the brake model in the ANSYS Coupled Field Transient environment. For a comprehensive assessment of brake behavior, our research considers two load approaches: constant long-term (20 s) with an influence factor in the form of thermal expansion as a result of contact pair friction; linear load from the pads on the disс with a corresponding increase in pressure up to the moment when the rotation of the system is blocked. Our research presents an assessment of the rotor ventilation channels influence on the nature of the contact spot with the brake pads (open far-field contact, sliding contact, sticking contact, etc.). In addition, it is demonstrated that despite the linear increase in pads pressure on the rotor, the graphs of temperatures, volume (thermal expansion) and stresses are of parabolic character with a disproportionate increase in indicators. Such a result forces us to come to the conclusion that it is not possible to predict the behavior of the brakes based on the analysis during a short period of time of the experiment - conducting long-term analytical studies is extremely important in the case of brakes
Deepak S. Hugar, U. B. Kadabadi, "Design and Thermal Analysis of Disc Brake for Minimizing Temperature", International Research Journal of Engineering and Technology (IRJET), Volume: 04, Issue: 07,July -2017
Kang, H.; Jung, T.; Hong, Y.; Park, S. Effect of Cross-drilled Hole Shape on Crack of Disс Brake Rotor. J. Korean Soc. Automot. Eng. 2018, 26, 67–76.
Lee, H.-H. Finite Element Simulations with ANSYS Workbench 2021: Theory, Applications, Case Studies; SDC Publications: Gunpo-si, Korea, 2021.
Jaenudin, J. Jamari, M. Tauviqirrahman, "Thermal Analysis of Disc Brakes using Finite Element Method", American Institute of Physics, 1788, 030028 (2017); doi: 10.1063/1.4968281.
Reddy, V.C.; Reddy, M.G.; Gowd, G.H. Modeling and analysis of FSAE car disc brake using FEM. Int. J. Emerg. Technol. Adv. Eng. 2013, 3, 383–389.
Santosh Kumar Kallepalli, Harish Musti, DR.K.Sudhakar Reddy, "Enhancement in Design and Thermal Analysis Of Disc Brake Rotor", International Journal Of Engineering Sciences & Research Technology, February, 2017.
Mr. Sumeet Satope, Akshaykumar Bote, Swapneel D. Rawool, "Thermal Analysis of Disc Brake", International Journal for Innovative Research in Science & Technology, Volume 3, Issue 12, May 2017.
Swapnil Umale,Dheeraj Varma, "Disc Brake Rotor Selection through Finite Element Analysis", International journal of recent trends in engineering & research, Volume 02, Issue 4; April - 2016.
Nakatsuji T, Okubo K, Fujii T, Sasada M, Noguchi Y. Study on crack initiation at small holes of one-piece brake discs. SAE, Inc.; 2002. p. 01–0926.
Laraqi N. Velocity and relative contact size effect on the thermal constriction resistance in sliding solids. ASME J Heat Transfer 1997;119:173–7.
Gwak, W.-G.; Hong, C.-K.; Kim, Y.-J. Influence of the Braking Time on the Soundness of Ventilated Disc Brake Systems. J. Auto-Veh. Saf. Assoc. 2016, 8, 7–12.
Belghazi H, El Ganaoui M, Labbe JC. Analytical solution of unsteady heat conduction in a two-layered material in imperfect contact subjected to a moving heat source. Int J Therm Sci 2010;49(2):311–8.
Ali Belhocine, Mostefa Bouchetara. Investigation of temperature and thermal stress in ventilated disc brake based on 3D thermomechanical coupling model. Department of Mechanical Engineering, USTO Oran University, L.P 1505 El-Mnaouer, USTO, 31000 Oran, Algeria.