Design synthesis of non-symmetrically loaded high-performance disc brakes: Part 2: Finite element modelling

Abstract

The prediction of the behaviour of wheel-mounted disc brakes is particularly complex due to non-symmetrical heat input, making disc coning during braking inevitable. Furthermore, severe brake applications cause high local temperatures and stresses, resulting in disc material yielding and permanent disc coning. To ensure adequate brake operation, disc coning during braking and permanent disc coning must be kept within acceptable limits. Obviously, excessive hub stresses must also be avoided, to ensure structural integrity throughout expected brake life. In order to predict disc permanent coning, it is necessary to model macro thermal effects, i.e. thermoelastic instability. The paper deals with different finite element (FE) modelling techniques and measurements of disc material properties, establishing efficient methodology for the prediction of wheel-mounted disc performance. The procedure developed is widely based on a standard FE code, with subroutines developed for data preparation, processing and visualization. This approach, combined with the efficiency and robustness of the methodology, is very suitable for industrial use, reducing risks, costs and development time.