Thermo-mechanical Analysis of Railway Brake Disc with the Consideration of Contact Pressure Distribution and Non-uniform Heat Flux Density

doi:10.3901/JME.2023.03.165

Abstract

Abstract: The friction block arrangement has a significant influence on the thermo-mechanical response status of the brake disc. A thermo-mechanical simulation method considering the influence of contact pressure distribution and non-uniform heat flux density is proposed. The experimental test data obtained by the railway vehicle braking performance test bench is used to validate the correctness of the proposed method from the perspective of temperature. After that, the full-size finite element model of the railway disc brake system is established and the existing friction block arrangement is optimized. The results indicate that a reasonable arrangement of friction blocks can significantly reduce the highest temperature and stress, improve the distribution of temperature and stress on the brake disc, and provide good braking performance. This work can provide a fast and effective simulation method for thermo-mechanical analysis of railway disc brake systems and provide guidance for friction block arrangement optimization.

Key words: brake disc, friction block arrangement, contact pressure distribution, thermo-mechanical response, non-uniform heat flux density

CLC Number:

TH117

ZHANG Qinghe, LU Chun, WU Yuanke, ZHAO Jing, MO Jiliang. Thermo-mechanical Analysis of Railway Brake Disc with the Consideration of Contact Pressure Distribution and Non-uniform Heat Flux Density[J]. Journal of Mechanical Engineering, 2023, 59(3): 165-175.

References

[1] 王文静,谢基龙,刘志明,等. 基于循环对称结构制动盘的三维瞬态温度场仿真[J]. 机械工程学报,2002,38(12):131-134.
WANG Wenjing,XIE Jilong,LIU Zhiming,et al. 3-D transient temperature field analysis and calculation for brake disc with cyclic symmetric structure[J]. Journal of Mechanical Engineering,2002,38(12):131-134.
[2] QI H S,DAY A J. Investigation of disc/pad interface temperatures in friction braking[J]. Wear,2006,262(5):505-513.
[3] STRÖMBERG N. An Eulerian approach for simulating frictional heating in disc-pad systems[J]. European Journal of Mechanics/A Solids,2011,30(5):673-683.
[4] 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.
[5] 赵海燕,张海泉,汤晓华,等. 快速列车盘型制动热过程有限元分析[J]. 清华大学学报,2005,45(5):589-592.
ZHAO Haiyan,ZHANG Haiquan,TANG Xiaohua,et al. Thermal FEM analysis of passenger railway car brake discs[J]. Journal of Tsinghua University,2005,45(5):589-592.
[6] 孟德建,张彬,徐杰,等. 制动钳及其约束对制动器热机耦合特性的影响[J]. 同济大学学报,2019,47(5):704-713.
MENG Dejian,ZHANG Bin,XU Jie,et al. Effect of brake caliper and its restraint on thermo-mechanical coupling characteristics of disc brake[J]. Journal of Tongji University,2019,47(5):704-713.
[7] 王国顺. 摩擦块分布方式对摩擦盘温度场和应力场的影响[J]. 润滑与密封,2014,39(3):43-47.
WANG Guoshun. The influence of friction block distribution mode on temperature and stress field of friction disk[J]. Lubrication Engineering,2014,39(3):43-47.
[8] 李月明,杨俊英,韩晓明,等. 接触面积和接触方式对制动盘温度场的影响[J]. 铁道机车车辆,2020,40(3):23-28.
LI Yueming,YANG Junying,HAN Xiaoming,et al. Influence of contact area and contact mode on temperature field of brake disc[J]. Railway Locomotive & Car,2020,40(3):23-28.
[9] 李继山,林祜亭,李和平. 高速列车合金锻钢制动盘温度场仿真分析[J]. 铁道学报,2006,28(4):45-48.
LI Jishan,LIN Huting,LI Heping. Simulation analysis on the alloy-forge steel brake disc temperature field for a high-speed train[J]. Journal of the China Railway Society,2006,28(4):45-48.
[10] 黄健萌,高诚辉,唐旭晟,等. 盘式制动器热-结构耦合的数值建模与分析[J]. 机械工程学报,2008,44(2):145-151.
HUANG Jianmeng,GAO Chenghui,TANG Xusheng,et al. Numerical modeling and analysis of the thermal-structure coupling of the disc brake[J]. Journal of Mechanical Engineering,2008,44(2):145-151.
[11] 潘公宇,王继业. 转动热源作用下的制动盘顺序热机耦合分析[J]. 机械设计与制造,2020(8):126-130.
PAN Gongyu,WANG Jiye. Sequential thermo-mechanical coupling analysis of brake disk under rotating heat source[J]. Machinery Design & Manufacture,2020(8):126-130.
[12] HONG H,KIM M,LEE H,et al. The thermo-mechanical behavior of brake discs for high-speed railway vehicles[J]. Journal of Mechanical Science and Technology,2019,33(4):1711-1721.
[13] GRZES P. Finite element analysis of disc temperature during braking process[J]. Acta Mechanica Et Automatica,2009,3(4):36-42.
[14] XIANG Z Y,CHEN W,MO J L,et al. The effects of the friction block shape on the tribological and dynamical behaviors of high-speed train brakes[J]. International Journal of Mechanical Sciences,2021,194:106184.
[15] WU Y K,XU J W,WANG X C,et al. The effect of damping components on the interfacial dynamics and tribological behavior of high-speed train brakes[J]. Applied Acoustics,2021,178(1):107962.
[16] 全鑫,莫继良,王安宇,等. 高速列车制动片摩擦块尺寸对制动噪声特性的影响[J]. 润滑与密封,2019,44(9):50-55.
QUAN Xin,MO Jiliang,WANG Anyu,et al. Effect of Friction block size of high-speed train brakes on noise characteristics[J]. Lubrication Engineering,2019,44(9):50-55.
[17] FAN Z Y,XIANG Z Y,TANG B,et al. Effect of surface modification on the tribological properties of friction blocks in high-speed train brake systems[J]. Tribology Letters,2021,69(1):1-19.
[18] 孙超,高飞,符蓉,等. 制动闸片结构特征的表征方法研究[J]. 铁道机车车辆,2012,32(4):49-54.
SUN Chao,GAO Fei,FU Rong,et al. Research of structure characterization method of brake pad[J]. Railway Locomotive & Car,2012,32(4):49-54.
[19] WANG G,FU R. Impact of brake pad structure on temperature and stress fields of brake disc[J]. Advances in Materials Science and Engineering,2013,2013(1):1-9.
[20] DEGALLAIX G,DUFRÉNOY P,WONG J,et al. Failure mechanisms of TGV brake discs[C]//Key Engineering Materials. Trans Tech Publications Ltd,2007,345:697-700.
[21] YANG Z,HAN J,LI W,et al. Analyzing the mechanisms of fatigue crack initiation and propagation in CRH EMU brake discs[J]. Engineering Failure Analysis,2013,34:121-128.
[22] HAN M J,LEE C H,PARK T W,et al. Low and high cycle fatigue of automotive brake discs using coupled thermo-mechanical finite element analysis under thermal loading[J]. Journal of Mechanical Science and Technology,2018,32(12):5777-5784.
[23] WU S C,ZHANG S Q,XU Z W. Thermal crack growth-based fatigue life prediction due to braking for a high-speed railway brake disc[J]. International Journal of Fatigue,2016,87:359-369.
[24] 张立军,陈远,刁坤,等. 盘式制动器接触压力与热机耦合特性仿真分析[J]. 同济大学学报,2013,41(10):1554-1561.
ZHANG Lijun,CHEN Yuan,DIAO Kun,et al. Computational investigation into disc-pads pressure distribution and thermomechanical coupling characteristics of brake pads in disc brake[J]. Journal of Tongji University,2013,41(10):1554-1561.
[25] CHO S K,CHOI J H,LEE Y M,et al. Life evaluation of a disk brake of railway vehicles considering pressure distributions at a frictional surface[J]. Key Engineering Materials,2007,84:303-306.