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Finite Element Modelling of Ventilated Brake Disc Hot Spotting

Hot spotting of automotive disc brakes is an undesired thermal localisation phenomenon, which is a challenge for numerical modelling in terms of both accuracy and efficiency especially for complex disc geometry. In this research, the aim was to develop a computationally efficient finite element (FE) approach for 2-piece pin-mounted ventilated disc hot spot prediction with acceptable accuracy enabling parametric studies to contribute to the knowledge of the complex mechanisms. A time reduction strategy for the simulations was established by incorporating an axisymmetric brake pad assumption with material scaling factor and the friction characteristics were defined by a user-subroutine. The computing accuracy and efficiency of this method were then verified by comparing with traditional FE models. 2D in-plane, 2D out-of-plane, and 3D models were performed to investigate the effects of ventilated disc hot spotting, radial hot spot/band migration, and hot spotting of realistic complex disc geometry respectively. Both 2D and 3D results were validated using experimental results based on a laboratory dynamometer and showed good correlation. The results suggested that adequate modelling of friction pair contact pressure distribution and the subsequent non-uniform heat generation is essential for hot spot simulation; speed was identified as the determinant for the number of hot spots, whereas hot spot temperature was determined by energy level. Furthermore, recommendations for vent design, pins, disc run-out, cooling, material selection, wear rate, pad length and loading distribution were given. Finally, hot spotting and hot band migration cause-effect chains were established based on the results and discussion. / Appendix 1 and Appendix 2 are unavailable online due to copyright restrictions.

Identiferoai:union.ndltd.org:BRADFORD/oai:bradscholars.brad.ac.uk:10454/13340
Date January 2017
CreatorsTang, Jinghan
ContributorsBryant, David, Qi, Hong Sheng
PublisherUniversity of Bradford, Faculty of Engineering and Informatics University of Bradford
Source SetsBradford Scholars
LanguageEnglish
Detected LanguageEnglish
TypeThesis, doctoral, PhD
Rights<a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/"><img alt="Creative Commons License" style="border-width:0" src="http://i.creativecommons.org/l/by-nc-nd/3.0/88x31.png" /></a><br />The University of Bradford theses are licenced under a <a rel="license" href="http://creativecommons.org/licenses/by-nc-nd/3.0/">Creative Commons Licence</a>.

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