Research on Finite Element Simulation of Braking Process of High Speed Train Brake Disc and Influence of Surface Scratch on Stress Field

doi:10.3901/JME.2018.12.042

Abstract

Abstract: Scratch is the main failure form of the brake disc in the alpine environment of high-speed train. The braking process of brake disc is simulated by finite element method, which contributes to study and solution of the brake disc failure problem. However, the effect of scratch on performance of the brake disc is rarely studied. The influence of the position, depth and notch angle on the temperature field and stress field of the brake disc during emergency braking was studied by using the sub model technique in ABAQUS software. The results showed that under the same fillet radius (r=0.1 mm), the influence degree of the maximum equivalent stress of the brake disc was the depth of the scratch > scratch position > notch angle. The maximum equivalent stress increased with the increase of the depth of the scratch, while the scratch depth reached a certain, the maximum equivalent stress of the brake disc had low sensitivity to notch angle. The maximum equivalent stress exceeded the yield strength of the brake disc material when the scratch was in the radius of 247.5 mm, notch angle 30° and the depth was 3 mm.

Key words: brake disc in the alpine environment, scratch, stress field, temperature field

CLC Number:

U238

MENG Fanhui, LIU Yan, WU Ying, MA Yuanming, CHEN Hui. Research on Finite Element Simulation of Braking Process of High Speed Train Brake Disc and Influence of Surface Scratch on Stress Field[J]. Journal of Mechanical Engineering, 2018, 54(12): 42-48.

References

[1] 李继山. 高速列车合金锻钢制动盘寿命评估研究[D]. 北京:中国铁道科学研究院, 2006. LI Jishan. Study on life estimation for alloy forging steel brake disc of High-speed train[D]. Beijing:China Academy of Railway Sciences, 2006.
[2] 王晓东. 基于ANSYS的高速列车制动盘数值模拟[D]. 成都:西南交通大学, 2009. WANG Xiaodong. Numerical simulation of brake discs of High-speed trains based on ANSYS[D]. Chengdu:Southwest Jiaotong University, 2009.
[3] 杨强. 列车制动盘温度场和应力场仿真与分析[D]. 北京:北京交通大学, 2009. YANG Qiang. Simulation and analysis of temperature field and stress field of train brake disc[D]. Beijing:Beijing Jiaotong Unviersity, 2009
[4] ABDI R E, SAMROUT H. Anisothermalmodelling applied to brake discs[J]. International Journal of Non-Linear Mechanics, 1999, 34(5):795-805.
[5] ABDI R E, SAMROUT H. A non-linear kinematic hardening model for a steel under complex loadings[J]. Computers & Structures, 2000, 76(5):675-681.
[6] 张涛,王梦昕,丁亚琦,等. 动车制动盘温度场和热应力场的耦合分析[J]. 兰州交通大学学报,2011,30(6):119-122. ZHANG Tao, WANG Mengxin, DING Yaqi, et al. Coupling analysis of temperature and stress fields for brake disc on power car[J]. Journal of Lanzhou Jiaotong University, 2011,30(6):119-122.
[7] PEVEC M,POTRC I,BOMBEK G, et al. Prediction of the cooling factors of a vehicle braked is candits influenceon the results of a thermal numerical simulation[J]. International Journal of Automotive Technology,2012,13(5):725-733.
[8] BELHOCINE A,BOUCHETARA M. Investigation of temperature and thermal stress in ventilated disc brake based on 3D thermomechanical coupling model[J]. Ain Shams Engineering Journal, 2013,4(3):475-483.
[9] 周素霞,杨月,谢基龙. 高速列车制动盘瞬态温度和热应力分布仿真分析[J]. 机械工程学报,2011,47(22):126-131. ZHOU Suxia, YANG Yue, XIE Jilong. Analysis of transient temperature and thermal stress distribution on the high-speed strain brake disk by simulation[J]. Journal of Mechanical Engineering, 2011,47(22):126-131.
[10] 张新芳,李芾,孙树磊,等. 快速货车制动盘热应力分析[J]. 铁道机车车辆,2012,32(1):35-38. ZHANG Xinfang, LI Fu, SUN Shulei, et al. Thermal stress analysis of brake discs in rapid speed wagon[J]. Railway Locomotive & Car, 2012,32(1):35-38.
[11] 李继山,顾磊磊,焦标强,等. 350Km/h高速列车轮装制动盘仿真分析[J]. 铁道机车车辆,2013,33(2):32-37. LI Jishan, GU Leilei, JIAO Biaoqiang, et al. Finite element analysis of the brake disc for 350km/h high-speed train[J]. Railway Locomotive & Car, 2013,33(2):32-37.
[12] 王国顺. 基于ABAQUS的列车盘型制动的温度场分析[J]. 润滑与密封,2013,38(3):36-38. WANG Guoshun. Analysis on temperature field of train disc brake based on ABAQUS[J]. Lubrication Engineering, 2013,38(3):36-38.
[13] 赵愿军. 盘式制动器热力耦合瞬态温度场仿真与分析[D]. 武汉:华中科技大学,2013. ZHAO Yuanjun. Simulation and analysis of disc brake coupled thermal-stress transient temperature[D]. Wuhan:Huazhong University of Science and Technology, 2013.
[14] 李有堂,周强. 缺口参数对应力集中系数和疲劳缺口系数的影响[J]. 兰州理工大学学报,2013,39(5):159-161. LI Youtang, ZHOU Qiang. Effect of notch parameter on stress concentration factor and fatigue notch factor[J]. Journal of Lanzhou University of Technology, 2013, 39(5):159-161.

[1]	LIU Xin, ZHANG Jun, XU Binbin, LIU Hongguang, ZHAO Wanhua. Controlling Strategy of Preheating Temperature Field in Laser-assisted Machining Process [J]. Journal of Mechanical Engineering, 2024, 60(9): 218-228.
[2]	LI Ying, ZHANG Jiafang, ZHANG Zhaoyong, WANG Xincheng, ZHANG Jin, KONG Xiangdong. Design of Minimum Diameter of Piston Neck in Swashplate Axial Piston Pump [J]. Journal of Mechanical Engineering, 2024, 60(4): 430-437.
[3]	LU Haoran, ZOU Mengzhen, LI Zhe. Comparative Study of Long/Short Blade Lithium-ion Batteries Based on Electrochemical-thermal Coupling Model [J]. Journal of Mechanical Engineering, 2024, 60(20): 193-207.
[4]	PENG Wen, ZHANG Li, LI Xudong, LIU Jun, SUN Jie, ZHANG Dianhua. Thermal Behavior and Temperature Uniformity of Rolling Parts during Edge Induction Heating [J]. Journal of Mechanical Engineering, 2024, 60(2): 119-131.
[5]	GAO Zhuanni, WANG Leilei, LI Xiang, LIU Zhiqiang, Lü Feiyue, LI Yifan, ZHAN Xiaohong. Effect of Thermal Cycle and Temperature Gradient on Solidification Microstructure of Deposition Layer during 7075 Aluminum Alloy Laser Wire Additive Manufacturing [J]. Journal of Mechanical Engineering, 2024, 60(1): 96-118.
[6]	WANG Huipeng, ZHU Penghua, SHU Fengyuan, HE Peng, LIU Cunyu. Simulation and Performance Research of Laser Cladding Temperature Field on 65Mn Steel Surface [J]. Journal of Mechanical Engineering, 2023, 59(7): 216-224.
[7]	CUI Yue, ZHU Liyan, HU Bin, WEI Dong, DU Yanxia, GUI Yewei. Research on Ultrasonic Synchronous Measurement of Temperature Field and Thickness in High-temperature Structure [J]. Journal of Mechanical Engineering, 2023, 59(22): 215-221.
[8]	REN Jie, GE Su, GUO Baofeng, JIN Miao. New Method and Application of Stress Field Calculation for Large Forgings [J]. Journal of Mechanical Engineering, 2023, 59(14): 106-115.
[9]	YUAN Songmei, SHAO Mengbo, LI Qilin, GAO Xiaoxing, CHEN Bochuan. An Simulation and Experimental Study on Ultrasonic Vibration-assisted Scratching of Titanium Carbide Particle-reinforced Steel Matrix Composites [J]. Journal of Mechanical Engineering, 2022, 58(7): 246-257.
[10]	ZHOU Suxia, TONG Xin, SUN Yuduo, SHAO Jing. Research on New Structure of High-speed Train Brake Disc Based on Phase Change Heat Storage Principle [J]. Journal of Mechanical Engineering, 2022, 58(6): 202-210.
[11]	GUO Dongmei, GONG Xuebei, ZHAO Weidong. Snap-through Buckling Analysis of P-FGM Shallow Spherical Shells under Thermomechanical Loads [J]. Journal of Mechanical Engineering, 2022, 58(24): 111-120.
[12]	ZHOU Changjiang, WANG Haoye, JIN Guanghu, AI Yongshen. Calculation Method of Contact Fatigue Life of Spiral Bevel Gears Considering Residual Stress [J]. Journal of Mechanical Engineering, 2022, 58(23): 28-38.
[13]	ZHANG Xiaosong, CHEN Shuaifeng, LI Wang, SONG Hongwu, ZHANG Shihong, WEI Zuoshan. Study on Improving the Formability of 2B06 Aluminum Alloy Sheet by Local Hardening Effect Using Laser Heat Treatment [J]. Journal of Mechanical Engineering, 2022, 58(20): 250-259.
[14]	ZHOU Suxia, SHAO Jing, TONG Xin. Research on New Type of Brake Disc Dased on Continuous Braking on Long Ramps [J]. Journal of Mechanical Engineering, 2022, 58(20): 391-398.
[15]	XIAO Xudong, ZHANG Bolun, QIAO Dan, YANG Mingshun, GAO Tianyu. Influence of Fixed Constraint of Component on Peen Forming Deformation [J]. Journal of Mechanical Engineering, 2022, 58(12): 103-110.