Development of Disc Brake Rotors for Heavy- and Medium-Duty Trucks with High Thermal Fatigue Strength

Yamabe, Junichiro; Takagi, Masami; Matsui, Toshiharu; Kimura, Takashige; Sasaki, Masanori

doi:10.4271/2003-01-3372

Cited by 14 publications

(8 citation statements)

References 4 publications

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“…The heating on a surface of friction during braking leads to temperature shock that generates surface cracks [22,23]. Cleavage of the material in the process of thermal cracking results from tensile stresses when the friction elements are heated by the moving heat flux.…”

Section: Introductionmentioning

confidence: 99%

Temperature and thermal stresses in a pad/disc during braking

Yevtushenko¹,

Kuciej²

2010

Applied Thermal Engineering

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ACCEPTED MANUSCRIPT 2 ABSTRACTA two-element model of braking process for a tribosystem consisting of the pad (the strip) sliding with the time-dependent velocity (braking at uniform retardation) on a surface of the disc (the semi-space) is studied. The dependences of temperature and thermal stresses on the boundary conditions on upper surface of the ceramic-metal strip were investigated. It was proved that there is a possibility of applying the obtained results to modelling of a thermal cracking of the frictional elements during braking.

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Section: Introductionmentioning

confidence: 99%

Temperature and thermal stresses in a pad/disc during braking

Yevtushenko¹,

Kuciej²

2010

Applied Thermal Engineering

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“…Premature failure of truck brake discs due to macroscopic cracks is a matter of major concern. [1][2][3] In order to improve disc performance, the design and material of brake discs are generally investigated. This study was carried out with the aim of developing new material solutions for increasing the lifespan of discs.…”

Section: Contextmentioning

confidence: 99%

Braking performance and influence of microstructure of advanced cast irons for heavy goods vehicle brake discs

Collignon

Regheere

Cristol

et al. 2013

Proceedings of the Institution of Mechanical Engineers, Part J:

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It is well known that truck brakes dissipate several megajoules of energy every few seconds, which leads to high thermal stresses in the rubbing parts. Therefore, premature failure by cracking of truck brake discs is a matter of major concern. Improving the design and material of brake discs may enhance braking performance. This study focuses on the latter aspect and was carried out with the aim of developing new material solutions for increasing disc lifespan. To do so, braking experiments were conducted on a specially designed braking tribometer. The brake pads that were used were made from a commercial brake lining material. Two advanced cast irons with different graphite morphology were studied in comparison with the lamellar grey cast iron commonly used for brake disc. To verify the friction and thermal behaviour of the two cast irons, braking tests were carried out as a series of stop-brakings with increasing dissipated power and energy and as a series of slowdowns to achieve heat accumulation effects. Thermal phenomena were studied through bulk temperature measurements and infrared monitoring of the disc surface. Friction behaviour, braking performance and variations in thermal loading were analysed in relation to the level of energy dissipation. The two advanced cast irons and lamellar cast iron had equivalent braking performance and stored similar amounts of heat, according to their thermophysical properties. Observations of the rubbing surfaces indicated damage mechanisms affected by the graphite morphology. Less plastic deformation on the surface was observed with an interdendritic graphite.

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“…rounded, graphite particles in the microstructure divided by the total number of graphite particles). 14 Furthermore, the thermal diffusivity has been found to be dependent on the flake morphology, 15,16 increasing with increasing size of the graphite flakes. An increase in the carbon content increases the thermal diffusivity but also increases the flake size and the number of flakes at a given cooling rate.…”

Section: Introductionmentioning

confidence: 99%

“…An increase in the carbon content increases the thermal diffusivity but also increases the flake size and the number of flakes at a given cooling rate. However, a drawback is that an increased size of the graphite flakes is directly linked to the strength in tension, since the flakes act like small cracks in the material, 16 limiting the life.…”

Section: Introductionmentioning

confidence: 99%

Modelling of grey cast iron for application to brake discs for heavy vehicles

Gigan

Ekh

Vernersson

et al. 2016

Proceedings of the Institution of Mechanical Engineers, Part D:

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Cast iron brake discs are commonly used in the automotive industry, and efforts are being made to gain a better understanding of the thermal and mechanical phenomena occurring at braking. The high thermomechanical loading at braking arises from interaction between the brake disc and the brake pads. Frictional heating generates elevated temperatures with a non-uniform spatial distribution often in the form of banding or hot spotting. These phenomena contribute to material fatigue and wear and possibly also to cracking. The use of advanced calibrated material models is one important step towards a reliable analysis of the mechanical behaviour and the life of brake discs. In the present study, a material model of the Gurson–Tvergaard–Needleman type is adopted, which accounts for asymmetric yielding in tension and compression, kinematic hardening effects, viscoplastic response and temperature dependence. The material model is calibrated using specimens tested in uniaxial cyclic loading for six different temperatures ranging from room temperature to 650 °C. A special testing protocol is followed which is intended to activate the different features of the material model. Validation of the model is performed by using tensile tests and thermomechanical experiments. An application example is given where a 10° sector of a brake disc is analysed using the commercial finitie element code Abaqus under a uniformly applied heat flux on the two friction surfaces. The results indicate that the friction surface of the hat side and the neck can be critical areas with respect to fatigue for the uniform heating studied.

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Development of Disc Brake Rotors for Heavy- and Medium-Duty Trucks with High Thermal Fatigue Strength

Cited by 14 publications

References 4 publications

Temperature and thermal stresses in a pad/disc during braking

Temperature and thermal stresses in a pad/disc during braking

Braking performance and influence of microstructure of advanced cast irons for heavy goods vehicle brake discs

Modelling of grey cast iron for application to brake discs for heavy vehicles

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