Theoretical Modeling and FEM Analysis of the Thermo-mechanical Dynamics of Ventilated Disc Brakes

Prediction and analysis of the thermo-mechanical coupling behavior in friction braking system is very important for the design and application of vehicle brakes, such as brake judder, brake squeal, brake wear, brake cracks, brake fade. This paper aims to establish a macro-structural model of the thermo-mechanical dynamics of the ventilated disc brake with asymmetrical outer and inner disc thickness, taking into account the friction-velocity curve of the disc pad couple acquired by testing. On the basis of finite elements analysis of the model, the predictions of the thermo-mechanical responses of the brake disc are presented, including disc transient temperature field and normal stress in radial, circular and axial directions, disc lateral deformation and disc thickness variation. Numerical predictions of the disc surface temperature and later distortion are compared with experimental measurements obtained by thermocouples and non-contact displacement sensors. Simulation results show complex interactions among frictional, thermal and mechanical dynamics, affected by the asymmetrical outer and inner disc thickness, which can be concluded from the detailed observation over the calculated curves. Such a model seems to be a suitable base for the study of the thermo-mechanical behavior and for the design of disc brakes.