Study of a segmented ventilation system of the brake disc and determination of the aerodynamic and heat exchange characteristics of the airflow

This study aims determine a relationship between the aerodynamic and heat exchange characteristics of the air flow in a segmented ventilation system of the brake disc with improved heat dissipation in the boundary layer of the air flow. Classical equations of heat and mass transfer in the boundary layer of the air flow cooling the brake disc ventilation chamber were used. The cooling performance of the system was assessed using the method of similarity. The obtained theoretical findings were confirmed by CFD-modelling. Mathematical models were developed for vented discs with both continuous grooves and slotted grooves. A criterion for assessing the performance of brake disc ventilation systems was proposed, consisting in turbulization of the air flow inside the device under study. According to the obtained analytical dependencies, a 20-fold acceleration of the air flow decreases the turbulization parameter by 1.24 times. An increase in the temperature difference in the boundary layer by 8 times leads to an increase in the turbulization parame-ter by 86.2 times. Using the criterion proposed for assessing the work performance, the aerodynamic and heat exchange characteristics of the system under study were calculated. As a result, a relationship between the design parameters of the segmented ventilation system and improved heat dissipation in the boundary layer of the cooling air flow is proposed. The conducted CFD modelling confirmed the aerodynamic characteristics of the system under study obtained theoretical-ly. This mathematical model together with the turbulization parameter can be used when both developing modern vented brake discs and assessing the existing cooling systems of friction units in order to minimize the possibility of reduced heat exchange processes.

Multiobjective optimization of internal and surface structure of high-speed and heavy-duty brake disc

The brake disc plays a crucial role to keep the stable braking of a high-speed and heavy-duty disc brake. There is always high temperature, brake vibration, and even serious deformation under braking pressure and frictional resistance. To improve brake performance, this paper aims to find new internal and surface structures of the brake disc. An equivalent moving load (EML) topology optimization method for internal structure is proposed. Topography optimization method oriented to displacement and stress control for surface structure is carried out. Multiobjective functions containing thermal-structural coupled rigidity and natural frequency of the brake disc are established in the internal and surface structure optimizations. Internal and surface structures of the brake disc are optimized, and the mechanic properties of the brake disc are improved. Thermal-structural coupling and modal analyses are verified with high-speed and heavy-duty brake working conditions. The results show that new brake disc structures meet the requirements, and the effectiveness of the proposed EML topology optimization and topography optimization methods has been proved.

Review of the coatings used for brake discs regarding their wear resistance and environmental effect

Wear of a friction pair of brake (brake disc and pads), in addition to reducing the active safety of vehicles, leads to the formation of particles that can affect the environment and human health. In addition to the technologies that are being developed for the collection of particles created by the wear of brakes during braking process, today new materials are being introduced, as well as various technologies for processing friction pairs with the aim of reducing brake wear and thus the formation of particles. Furthermore, today, technologies for coating (cladding) the friction surfaces of disc brakes with some materials are increasingly applied and researched, in order to reduce the wear intensity (wear rate) of disc brakes, i.e. the emission of particles created by wear of friction pairs. The aim of this paper is to analyse and review different deposition techniques and materials used for brake discs coatings, as well as the effect it has on the wear rate of friction pair. There are many coating deposition techniques, and special attention is paid to the technology of laser hardfacing of brake rotors.

Comparative Analysis of Temperature Fields in Railway Solid and Ventilated Brake Discs

A new approach to numerical simulation using the finite element method (FEM) for the rotational motion of discs for railway vehicle disc brake systems was proposed. For this purpose, spatial models of transient heating due to the friction of such systems with solid and ventilated discs were developed. The performed calculations and the results obtained allowed justification of the possibility of simplifying the shape of the ventilated brake disc through elimination of ventilation channels. This contributes to a significant reduction in computational time, without compromising the accuracy of the results. The spatial and temporal temperature distributions in the ventilated and the solid disc of the same mass were analyzed. The share of energy dissipated due to convection and thermal radiation to the environment in relation to the total work done during a single braking was investigated. The maximum temperature values found as a result of computer simulations were consistent with the corresponding experimental results.

RESEARCH ON MATERIAL FLOW-STRESS BEHAVIOR AND THE DIE-FORGING PROCESS FOR FORGED-STEEL BRAKE DISCS FOR HIGH-SPEED TRAINS

Due to the large size and complicated features, the brake discs of high-speed trains are difficult to forge, so a reasonable design of the process and the die parameter are prerequisites for successful forming. The flow stress of 23CrNiMoV, a forged-steel brake disc material for high-speed trains, was investigated by a uniaxial compression experiment on a Gleeble 1500 test machine. Based on the obtained flow-stress data, a series of numerical simulation analyses of the die forging of high-speed-train brake discs were carried out by using finite-element software. The effects of forging temperature, flash groove parameters and forming speed on the flow filling, forming load and temperature change of metal during die forging were studied. The simulation results were optimized and better process parameters were obtained. Based on the obtained process parameters, the simulation of the forming process was completed and a better forming quality was obtained.

Thermo-Structural Analysis of Brake Disc-Pad Assembly of an Automotive Braking System

Braking is a phenomenon of stabilizing a moving vehicle to rest by actuating the braking system. The available kinetic energy from the dynamic body is transformed into mechanical energy by the braking system which is further converted into thermal energy for its dissipation into the surroundings. During the process of braking, the frictional contact between the brake disc and brake pad creates enormous amount of heat elevating the temperature of the system to a higher level. The objective of this numerical study is to minimize the heat produced during the braking process. Three unique ventilated brake disc and two brake pad profiles were developed using PTC Creo modelling tool and were subjected to ANSYS workbench to evaluate its thermal and structural performance with a braking cycle time of 4.50 sec. Total deformation, equivalent stress, temperature distribution and total heal flux were assessed. Based on the study, ventilated disc 3 can be the possible design with either of the brake pad profiles for effective usage in the automotive braking system.

Interpretation of Non-Exhaust Brake Emission Standard: Laboratory Testing

Now there are more and more new energy vehicles on the road, compare to the traditional vehicles that use the oil to offer the power, the new energy vehicles use electric or hydrogen to offer the power, which have no exhaust pollution emission, but also have non-exhaust emission. Brake and tyre system are the special components of vehicles due to the frequent replacement, they are the main source of the non-exhaust emission. Brake system is one of the most important safety systems of vehicles. The system can reduce the speed of the vehicle and keep the vehicle stable when going downhill. Friction between brake disc and pads or shoes during driving creates small particles that are released into the atmosphere, soil and rivers. The particles have different dimensions, some element or matter inside maybe harmful to human and environment. So it is very important to know more about the non-exhaust brake emission. Here, we focus on the specification of GRPE-81-12 “Non-Exhaust Brake Emissions – Laboratory testing – Part 1: Inertia Dynamometer Protocol to Measure and Characterise Brake Emissions Using the WLTP-Brake Cycle” and do the detailed interpretation.

Energy balance of the airflow boundary layer in the brake disc ventilation

Airflow through the brake disc ventilation causes the formation of a boundary layer at the walls. It affects both the dynamic processes related to air exchange in the space between the walls and thermal processes associated with air insulation of the heated surfaces of the ventilation ducts. The present paper aims to develop a model for calculating plane airflow in a ventilation duct in polar coordinates. Using the Navier-Stokes equations and the equations of the energy balance of the airflow boundary layer, we succeeded in determining the elements that affect the intensity of changes in the air masses in the boundary layer and the elements that are responsible for the thermal conductivity of the thermal boundary layer of the airflow. Besides, we obtained an energy balance equation, which takes into account the enthalpy and thermodynamic parameters of the thermal boundary layer, as well as found the possibilities of influencing the heat exchange processes by minimizing factors of the heat-insulating boundary layer. Finally, we specified the dependence of the boundary layer temperature on the temperature of the walls of the brake disc ventilation. The obtained dependences lay the ground for formulating variants of the influence on the heat-insulating boundary layer of the airflow, namely, the design of a forced air supply system at different angles of attack into the ventilation cavity of the brake disc or the manufacture of ventilation ducts with complex geometry.