Failure analysis of a motorcycle brake disc

Boniardi, Marco; D’Errico, Fabrizio; Tagliabue, Chiara; Gotti, Giordano; Perricone, Guido

doi:10.1016/j.engfailanal.2005.04.012

Cited by 28 publications

(19 citation statements)

References 3 publications

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“…5,6 The hot spots and thermal fatigue caused by rapid increase and decrease of temperature are the main failure cause of the disc. 7,8 Therefore, achieving a better understanding of temperature evolution is an important topic in the design and application of brake disc.…”

Section: Introductionmentioning

confidence: 99%

Temperature evolution of the train brake disc during high-speed braking

Wang

Han

Liu

et al. 2019

Advances in Mechanical Engineering

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Temperature evolution of the train brake disc during high-speed braking was investigated using in situ experiments, theoretical analysis, and finite element modeling. The experimental results show that the temperature distribution on the friction surface experienced the formation of a hot ring first, then expansion and duration of the hot ring. Alternative hot spot and cold zone were observed on the friction surface, which is attributed to the local contact in the friction couple and heterogeneous heat dissipation condition in the disc. The corresponding maximum temperature in the disc increased rapidly first, kept stable then, and decrease slowly in the end. The one-dimensional heat conduction equation was applied to predict the maximum temperature variation and was found to be in agreement with the experimental results. Furthermore, the maximum temperature evolution and the temperature distribution of the disc at the braking time of 45 s were simulated by the finite element method, which is satisfactory. In additional, the temperature variation caused the corresponding fluctuation of instantaneous frictional coefficient and thermal stress distribution in the disc, which results in the thermal damages.

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Section: Introductionmentioning

confidence: 99%

Temperature evolution of the train brake disc during high-speed braking

Wang

Han

Liu

et al. 2019

Advances in Mechanical Engineering

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“…Quanto menor o valor da temperatura experimentado por um sistema de freio durante uma frenagem melhor é, pois desta forma o sistema fica menos sujeito a efeitos térmicos, como decaimento do coeficiente de atrito, comportamento não constante entre frenagens seguintes e trincas, como consequência da excessiva têmpera da martensita, devido às altas temperaturas das condições de trabalho (BONIARDI et al, 2005) [4]. Desta forma, o menor valor observado foi no vértice do cubo que representa o tratamento com disco de freio novo, pastilhas novas e pressão de contato de 0,10 MPa, cujo valor foi de 73,375ºC.…”

Section: A B Figuraunclassified

Aplicação de Técnicas de Planejamento de Experimentos para Otimização do Comportamento Tribológico e Térmico de Materiais de Atrito Durante o Processo de Frenagem

et al. 2018

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RESUMOSistemas de freio têm a finalidade de reduzir ou manter a velocidade de um veículo, levá-lo à imobilidade ou mantê-lo imóvel. O princípio básico dos sistemas de freios por atrito é a conversão da energia cinética do veículo em energia térmica. Neste estudo, buscou-se analisar os parâmetros de operação de um sistema de freio a disco para motocicletas utilizando-se um banco de ensaios baseado no procedimento Krauss, descrita pela norma ABNT NBR 6143/1995. Optou-se por conduzir um Experimento fatorial completo 2³, em que os três fatores de controle considerados (tipo de disco de freio, tipo de pastilha e o valor da pressão de acionamento da manete de freio) foram alterados deliberadamente em dois níveis cada. Analisou-se as propriedades dos materiais envolvidos novos e após um determinado tempo de uso, denominado materiais assentados. Para avaliar o desempenho do sistema de freio durante o processo de frenagem, analisaram-se duas variáveis de resposta simultaneamente: coeficiente de atrito e temperatura final. A partir dos experimentos, o desempenho tribológico mais satisfatório ocorreu para os materiais constituintes do par de atrito, disco e pastilhas, assentados, e um menor valor de pressão de acionamento da manete de freio. Já para a temperatura, o melhor resultado ocorreu para os materiais do par de atrito novo e um menor valor de pressão. Com o intuito de encontrar a melhor combinação dos níveis de cada fator que otimize o desempenho global destas duas variáveis resposta, foi proposta uma técnica de otimização de múltiplas respostas. Como resultado, obteve-se os níveis assentados do par de atrito e o menor valor de pressão como os capazes de otimizar as duas variáveis resposta simultaneamente. Por fim, o banco de ensaios foi adaptado com um motor de maior potência, o que possibilitou evidenciar e esclarecer mais sobre o efeito brake fade. Palavras-chave: Material de atrito, Frenagem, Sistemas de Freio, efeito fade ABSTRACTBrake systems are employed to reduce or maintain the speed of a vehicle, take it to stillness or keep it motionless. The basic principle of friction brake systems is the conversion of the kinetic energy of the vehicle into thermal energy. This study aimed to analyze the operating parameters of a disc brake system for motorcycles using a test bench based on the Krauss procedure described by ABNT NBR 6143/1995. It was decided to conduct a complete 2³ factorial experiment, in which the three control factors considered (type of brake disc, type of pad and the value of brake lever drive pressure) were deliberately altered in two levels each. The properties of the new materials were analyzed and after a certain time of use, called seated materials. To evaluate the performance of the brake system during the braking process, two response variables were analyzed simultaneously: friction coefficient and final temperature. From the experiments, the

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“…Thermal fatigue is a common failure mechanism in brake discs. Some published research papers deal with this specific problem from experimental and numerical perspectives, whereas others focus on failure analysis aspects . Temperature gradients and the intrinsic tangential constraint related to disc geometry are responsible for the formation of thermal stresses that, together with continued environmental exposure, can affect the fatigue life and the overall performance of brake discs in service, causing premature failures.…”

Section: Introductionmentioning

confidence: 99%

“…Some published research papers deal with this Nomenclature: Ac 1 , Ac 3 = critical temperatures of steels; FEM= finite element method; H1= heated area 1; H2= heated area 2; H3= heated area 3; R= stress ratio; Term= definition; ThF= thermal Fatigue; σ a = stress amplitude; σ m = Mean stress value specific problem from experimental and numerical perspectives, [9][10][11][12][13][14][15] whereas others focus on failure analysis aspects. [16][17][18][19] Temperature gradients and the intrinsic tangential constraint related to disc geometry are responsible for the formation of thermal stresses that, together with continued environmental exposure, can affect the fatigue life and the overall performance of brake discs in service, causing premature failures. The most evident consequence of ThF is the formation and propagation of microcracks and macrocracks in radial direction on the surfaces of discs.…”

Section: Introductionmentioning

confidence: 99%

Microstructural evolution and thermal fatigue resistance of grey cast iron

Casati

Faccin

Vedani

2017

Fatigue Fract Eng Mat Struct

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In the present work, thermal fatigue in grey cast iron has been investigated by means of a numerical and an experimental approach. Temperature gradients were generated within the material by means of a testing rig specifically designed for the experiments. The temperature gradients were responsible for the formation of severe stress fields that led to the failure of the specimens after a fairly low number of cycles.Crack growth was monitored during the tests, and the microstructure and hardness of samples were analysed after failure and compared with those of untested alloy. The repeated thermal cycles at peak temperatures of 600, 700, and 800°C led to important microstructural alterations of cast iron and to a drop in material hardness. The pearlite lamellae lost their original shape and became more fragmented.Oxygen-rich regions surrounding the graphite flakes were produced by microgalvanic corrosion mechanism.

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Failure analysis of a motorcycle brake disc

Cited by 28 publications

References 3 publications

Temperature evolution of the train brake disc during high-speed braking

Temperature evolution of the train brake disc during high-speed braking

Aplicação de Técnicas de Planejamento de Experimentos para Otimização do Comportamento Tribológico e Térmico de Materiais de Atrito Durante o Processo de Frenagem

Microstructural evolution and thermal fatigue resistance of grey cast iron

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