Numerical Simulation on Hardness Distribution for a FC250 Gray Cast Iron Brake Disc Casting and Its Experimental Verification

Abstract

The purposes of this study are to develop a technique of numerically simulating the hardness of a FC250 gray cast iron brake disc casting and verified by experimental measurements. As the numerical model is proven reliable, numerical experimentation is then conducted to homogenize the hardness distribution of a brake disc to obtain better casting quality. The Oldfield's model was adopted to simulate the nucleation and grain growth during solidification of the casting. A calibration brake disc casting was first made. By comparing the hardness of the calibration brake disc casting with the simulated results using different nucleation and growth coefficients ðA e ; B e Þ in Oldfield's model, the most appropriate set of values for A e and B e was obtained. Then, this set of values was applied to the hardness simulation of a test brake disc casting and confirmed by experimental measurements. Through this approach, a set of nucleation and growth coefficients was obtained for the brake disc casting. Subsequently, numerical simulations were conducted for the brake disc casting with different shake-out times to evaluate its distribution of hardness and an optimized shake-out time was then proposed based on the simulated results. The predictions of hardness were validated by comparison with experimental measurements and actual track testing.

The Vibration and Modal Analysis of the Disc Brake

“…5 that 12 order natural frequency of disc was close to the 14 order of the friction pad, the 17 order natural frequency of disc was close to the 16 order of the friction pad, the 4 order natural frequency of the friction pad was close to the 5 order of the support. If there is a corresponding external incentive effect, it is easy to cause resonance and to produce brake noise [4][5].…”

Modeling and Simulation of the Gray-to-White Transition during Solidification of a Hypereutectic Gray Cast Iron: Application to a Stub-to-Carbon Connection Used in Smelting Processes

“…Therefore, the hardness can be determined through the ultimate tensile strength by the following relation [34]:…”

“…The influence of alloying elements on the UTS of hypoeutectic and hypereutectic GCIs has been experimentally evaluated [32]. Combined microstructure evolution-mechanical properties models for hypoeutectic GCI have been developed [33][34][35]. In [33,34], hardness and tensile strength were estimated via correlations written as a function the maximum graphite flake length and alloy composition.…”

“…Combined microstructure evolution-mechanical properties models for hypoeutectic GCI have been developed [33][34][35]. In [33,34], hardness and tensile strength were estimated via correlations written as a function the maximum graphite flake length and alloy composition. In [35], hardness is predicted via a mixing law considering the ferrite, pearlite, graphite, carbide, and pure iron contributions, while the ultimate tensile strength is assumed to depend on the maximum graphite length and lamellar spacing.…”