Design of C/SiC Composite Brake Disc for AALRT Finite Element Method

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Addis Ababa University


Gray cast iron is commonly used brake disc material with high density that increase fuel consumption. It also generates heat easily during braking due to its lower specific heat capacity which affects its mechanical properties. The ever increasing demand for high speed trains from passengers and reduction of maintenance costs by operators means a compelling need to develop new disc brake materials with higher friction performance and longer service life. An interesting alternative are C/SiC composite materials characterized by lower wear rate and higher resistance to thermal shock. During braking kinetic energy transforms in to thermal energy resulting to intense heat and high temperature in the brake disc-pad interface. Thus, induced thermal loads determine thermo-elastic behavior of the railway disc brake structure. This paper is mainly concerned with design analysis of C/SiC composite material to study and evaluate the performance under severe braking conditions and there by assist in brake disc design and analysis. Geometric dimensions of AA LRT train disc are taken on to CATIA where the 3D model is imported to ANSYS for determining the temperature distribution, variation of stresses and deformation produced in the disc brake after applying the boundary conditions. The main boundary and initial condition are the heat flux on the braking surface of the disc and the force of the brake clamps. Two different disc designs are used, one solid and other the ventilated existing one to demonstrate the material response for each variant. The aim is to investigate the structural deformation of the brake disc due to combined effect of thermal expansion when subjected to temperature change during the braking cycle and thereby assist the railway industry in developing optimum and effective disc brake material. The results were found to be satisfactory.



Brake disc, stress, heat flux, C/SiC composite, reinforcement fibers, transient response, friction coefficient, contact pressure