Dynamic modelling for hydraulic disc brake with floating supported friction plate considering nonlinear tooth clearance impact

Abstract

Abstract Floating support friction plate is one of the critical working components in high power hydraulic disc brake (HDB). Under no braking condition, the impact between floating friction plate and the inner hub of HDB is inevitably occurs due to the teeth clearances. The impact force may increase excessively due to the expansion of clearance, which arouses the risk of teeth failure of friction plate and hub. Until now, an effective dynamic model for HDB with floating support friction plate is still lacking considering non-equally distributed clearances. In order to settle this problem, a new dynamic modelling method for HDB with floating friction plate is proposed considering the nonlinear impact due to non-equally distributed and time varying teeth clearances. In the proposed method, a nonlinear dynamic model for the entire transmission system is first established with the floating friction plate taken into consideration. Then a dynamic impact force calculation method for floating friction plate and spline of inner hub is presented, in which the coupled effect of tooth clearance expansion and indexing errors are studied. Furthermore, the influence of clearance expansion and operating conditions on the nonlinear characteristics of impact force and dynamic response is investigated. Finally, an impact force measurement experimental setup for floating friction plate and spline of the inner hub is established to verify the proposed dynamic modelling method. Results show that the predicted impact force based on the proposed method agrees well with the test data in both time domain waveform and spectrum. It is concluded that this paper presents an effective modelling method for hydraulic disc brake with floating friction plate, and the influence of nonlinear tooth clearance impact can be well studied.