Analytical and Finite Element Analysis of Surface Wear on Disc Brake Rotor
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Date
2015-04
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Addis Ababa University
Abstract
A particular type of dry contact condition, known as disc and pad brake in contact, in which exposed to wear. In this thesis the wear analysis of disc brake is analyzed by using analytical and finite element method during short brake condition. One particular existing disc brake design for a SUV car of model DD6470C is selected for the study. The dimensions, material property and maximum allowable speed and variable applied brake pressure of this car are used as an input both for analytical and finite element method. Analytical analysis of distribution of contact temperature along in radial direction of disc brake caused by applied heat flux is solved by using separation of variable method. Finite element model of disc and pad brake assembly is done using the CATIA software. Finite element simulation for contact pressure and von misses stress using ANSYS workbench for the case of the structural analysis of disc brake is done by applying only brake pressure and angular velocity. But, in the case of thermal-structural analysis the maximum contact temperature value of disc and pad is considered in addition to applied brake pressure. The contact pressure and von misses stress are calculated analytically and ANSYS workbench results are presented in contour plot and numerically. Contact pressure, von misses stress and wear depth are increasing as increasing of both brake pressure and contact temperature of disc in case of thermal-structural analysis. The structural analysis is less effect than that of thermal-structural analysis in all contact pressure, von misses stress and wear. Based upon the analytical and ANSYS workbench analysis, an analytical model of dry sliding wear was developed. A multi-aspect comparison between analytical and ANSYS workbench results were made. A good agreement between analytical and ANSYS workbench results shows that model provided a reliable prediction of the tribological systems of disc-pad contact. The critical point of contact for disc in contact with pad in the case of structural analysis is near to inner and outer radius of disc brake while thermal-structural is at 95.859mm along radial direction from its center. Thus, this study provides effective reference for design and engineering application of brake disc and brake pad.
Key words: Analytical analysis, finite element method, contact pressure, wear
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Keywords
Analytical analysis; finite element method; contact pressure; wear