Finite Element Method analysis application in identifying the causes of brake disc failure
More details
Hide details
1
Department of Automotive Engineering, Wrocław University of Science and Technology, Poland
2
Collegium Witelona, Collegium Witelona Legnica, Poland
3
Student, Wrocław University of Science and Technology, Poland
Submission date: 2023-06-02
Final revision date: 2023-11-06
Acceptance date: 2023-12-01
Online publication date: 2024-01-11
Publication date: 2024-05-18
Corresponding author
Wojciech Ambroszko
Department of Automotive Engineering, Wrocław University of Science and Technology, Poland
Combustion Engines 2024,197(2), 71-82
KEYWORDS
TOPICS
ABSTRACT
This article presents the results of brake disc tests aimed at identifying the causes of its failure. The first part of the article presents an analysis of the damageability of selected vehicle components, which showed that among the reported failures, the most failure was the braking system.
The assessment of the brake disc worn "properly" as a result of operation and the deformed brake disc after a very short period of operation, which was the subject of further analysis. The next part of the article presents issues related to the modeling of thermal loads, and then, trying to assess and search for the cause of abnormal wear of the brake system element, the use of the Finite Element Method for the analysis and assessment of brake disc wear was proposed. In the final part of the article, conclusions and directions for further work were formulated.
REFERENCES (29)
1.
Automotive engineer handbook. Elements and materials. WKŁ Warsaw 1990.
2.
Baranowski P, Damaziak K, Małachowski J. Brake system studies using numerical methods. Eksploat Niezawodn. 2013;15(4):337-342.
3.
Baranowski P, Damziak K, Malachowski J, Mazurkiewicz L, Kastek M, Piatkowski T et al. Experimental and numerical study of thermo-mechanical processes occurring on brake pad lining surfaces. WIT Trans Eng Sci. 2011;71(X):15-24.
https://doi.org/10.2495/SECM11....
4.
Belhocine A, Abdullah OI. Thermomechanical model for the analysis of disc brake using the finite element method in frictional contact. Multiscale Science and Engineering. 2020;2:27-41.
https://doi.org/10.1007/s42493....
5.
Chen Y, Gao F, Fu R, Su L, Han X et al. Braking-experimental study on the relationship between friction material type and brake disc temperature. Ind Lubr Tribol. 2022;74(8);975-984.
https://doi.org/10.1108/ILT-03....
6.
Djafri M, Bouchetara M, Busch C, Weber S. Effects of humidity and corrosion on the tribological behaviour of the brake disc materials. Wear. 2014;321:8-15.
https://doi.org/10.1016/j.wear....
7.
Gao CH, Lin XZ. Transient temperature field analysis of a brake in a non-axisymmetric three-dimensional model. J Mater Process Tech. 2002;129:513-517.
https://doi.org/10.1016/S0924-....
8.
Guru Murthy Nathi, Charyulu TN, Gowtham K, Satish Reddy P. Coupled structural/thermal analysis of disc brake. International Journal of Research in Engineering and Technology. 2012;1(4):539-553.
https://doi.org/10.15623/ijret....
9.
Informator Techniczny Bosch. Conventional brake systems of passenger cars. 2001 Edition.
10.
Jin P, Xue Y, Chen B, Wang L. An analytical solution of temperature near nuclear waste canister under three-dimensional heat transfer condition progress in nuclear energy. Prog Nucl Energ. 2021;143:104051.
https://doi.org/10.1016/j.pnuc....
11.
Kirillov PL, Ninokata H. Heat transfer in nuclear thermal hydraulics. Thermal-hydraulics of water-cooled nuclear reactors. Woodhead Publishing. 2017:357-492.
https://doi.org/10.1016/C2015-....
12.
Kwaśniowski S, Sroka ZJ, Zabłocki W. Thermal load modeling in internal combustion engine components. Publishing House of Wrocław University of Science and Technology. Wroclaw 1999.
13.
Lu Q. A Finite Element approach for nonlinear, transient heat conduction problems with convection, radiation, or contact boundary conditions. Ann Nucl Energy. 2023;193:110009.
https://doi.org/10.1016/j.anuc....
15.
Muthu Visakan M, Mahesh Kumar U, Sivadasan VK. Review on braking system in railways. International Research Journal of Engineering and Technology. 2021;8(7):2333-2339.
https://www.irjet.net/archives....
17.
Pinca-Bretotean C, Bhandari R, Sharma C, Dhakad SK, Cosmin P, Sharma AK. An investigation of thermal behavior of brake disk pad assembly with Ansys. Mater Today-Proc. 2021;47(10):2322-2328.
https://doi.org/10.1016/j.matp....
18.
Popescu FD, Radu SM, Andraș A, Brînaș I, Budilică DI, Popescu V. Comparative analysis of mine shaft hoisting systems brake temperature using finite element analysis (FEA). Materials. 2022;15(9):3363.
https://doi.org/10.3390/ma1509....
19.
Qu J, Wang W, Wang B, Li G, Jiao B. Analysis of the axial load of bolts of wheel-mounted brake discs of high-speed trains. Eng Fail Anal. 2022;137:106250.
https://doi.org/10.1016/j.engf....
20.
Riva G, Varriale F, Wahlström J. A Finite Element Analysis (FEA) approach to simulate the coefficient of friction of a brake system starting from material friction characterization. Friction. 2021;9(1):191-200.
https://doi.org/10.1007/s40544....
21.
Rusiński E, Czmochowski J, Smolnicki T. Advanced Finite Element Method in load-bearing structures. Publishing House of Wrocław University of Science and Technology. Wroclaw 2000.
22.
Ścieszka S. Friction brakes. Material, design, and tribological aspects. Library of Maintenance Problems. Gliwice 1998.
23.
Tauviqirrahman M, Muchammad M, Setiazi T, Setiyana B, Jamari J. Analysis of the effect of ventilation hole angle and material variation on thermal behavior for car disc brakes using the finite element method. Results in Engineering. 2023;17:100844.
https://doi.org/10.1016/j.rine....
24.
Tripathi VK, Saini R, Joshi UK. Design and analysis of ventilated disc brake by using different materials: a review. International Journal for Research in Applied Science and Engineering Technology. 2023;11:627-631.
https://doi.org/10.22214/ijras....
25.
Usmani D, Mohan R, Mewada CS, Goga G. A comprehensive literature review on the recent advances in braking systems technology using FEA. J Phys Conf Ser. 2023;2484.
https://doi.org/10.1088/1742-6....
26.
Walczak S, Wolff A. Theoretical and experimental analysis of heat exchange in automotive brakes. Doctoral Dissertation. Warsaw University of Technology, Faculty of Automotive and Construction Machinery Engineering. Warsaw 2001.
27.
Wang Q, Wang Z, Mo J, Zhang L. Nonlinear behaviors of the disc brake system under the effect of wheel−rail adhesion. Tribol Int. 2022;165:107263.
https://doi.org/10.1016/j.trib....
28.
Yin J, Lu C, Mo J. Comprehensive modeling strategy for thermomechanical tribological behavior analysis of railway vehicle disc brake system. Friction. 2024;12:74-94.
https://doi.org/10.1007/s40544....
29.
Zemlik M, Dziubek M, Pyka D., Konat Ł, Grygier D. Case study of accelerated wear of brake discs made of grey cast iron characterized by increased thermal stability. Combustion Engines. 2022;190(3):45-49.
https://doi.org/10.19206/CE-14....