Non-Axisymmetric Modelling of Moving Heat Source for Spatial and Temporal Investigation of Temperature in Railway Vehicles Disc Brake

Abstract

Railway disc brake is vulnerable to surface damages including fade, wear, squeal, thermal cracks and fatigue being just few of them. To counteract these negative consequences, reliable thermal model that can accommodate space and time variables is essential. The aim of this study is to develop new non-axisymmetric moving heat source and compare its efficiency with pre-existing traditional models. Factors responsible for temperature spatial and temporal variation are identified first and then programmed in ANSYS APDL similar capability to a FORTRAN. Heat flux and convection coefficients are calculated by empirical equations and stored in parameters and arrays for later use, based on small time and pad angular increment. The modelling is to successfully solve the problems in traditional models by estimating surface temperature difference as high as 49 °C, within acceptable computation time. Besides, its consideration of radial distance reported variations from traditional models as high as 10% and 60% in moving heat source and axisymmetric, respectively. And, it is also verified with the literature within acceptable variation. Finally, it is suggested that the model can be applied in conducting pad geometry optimization, thermal stress and fatigue life of disc brake.

Keywords

ANSYS APDL / Disc brake / Finite element / Spatial temperature variation / Moving heat source

References

[1] Rao VTVSR, Ramasubramanian H, Seetharamu KN. Analysis of temperature field in brake disc for fade assessment. Wärme Stoffübertrag, 1989, 24(1): 9-17

[2] Benseddiq N, Weichert D, Seidermann J, Minet M. Optimization of design of railway disc brake pads. Proc Inst Mech Eng Part F J Rail Rapid Transit, 1996, 210(1): 51-61

[3] Dufrénoy P, Bodovillé G, Degallaix G. Damage mechanisms and thermomechanical loading of brake discs. Eur Struct Integr Soc, 2002, 29(C): 167-176

[4] Gigan G, Norman V, Ahlström J, Vernersson T. Thermomechanical fatigue of grey cast iron brake discs for heavy vehicles. Proc Inst Mech Eng Part D J Automob, 2019, 233(2): 453-467

[5] Deressa KT, Ambie DA (2021) Thermal load simulations in railway disc brake: a systematic review of modelling temperature, stress and fatigue, Arch Comput Methods Eng

[6] Tang J, Bryant D, Qi H, Whiteside B, Babenko M. Simplified three-dimensional finite element hot-spotting modelling of a pin-mounted vented brake disc: an investigation of hot-spotting determinants. Proc Inst Mech Eng Part D J Automob Eng, 2018, 232(7): 877-895

[7] Gao CH, Lin XZ. Transient temperature field analysis of a brake in a non-axisymmetric three-dimensional model. J Mater Process Technol, 2002, 129(1–3): 513-517

[8] Cho C, Ahn S. Transient thermoelastic analysis of disk brake using the fast Fourier transform and finite element method. J Therm Stress, 2002, 25(3): 215-243

[9] Li Z, Han J, Yang Z, Pan L. The effect of braking energy on the fatigue crack propagation in railway brake discs. Eng Fail Anal, 2014, 44: 272-284

[10] Yuan Z, Tian C, Wu M, Wang G (2021) A modified uniformly distributed heat source method for predicting braking temperature of railway brake disc, Int J Rail Transp, pp. 1–14

[11] Gao CH, Huang JM, Lin XZ, Tang XS. Stress analysis of thermal fatigue fracture of brake disks based on thermomechanical coupling. J Tribol, 2007, 129(3): 536-543

[12] Pan G, Cai R (2018) Thermal stress coupling analysis of ventilated disc brake based on moving heat source, Adv Mater Sci Eng, 2018.

[13] Yevtushenko AA, Kuciej M, Grzes P, Wasilewski P. Temperature in the railway disc brake at a repetitive short-term mode of braking. Int Commun Heat Mass Transf, 2017, 84: 102-109

[14] Adamowicz A, Grzes P. Influence of convective cooling on a disc brake temperature distribution during repetitive braking. Appl Therm Eng, 2011, 31(14–15): 2177-2185

[15] Mahmoudi T, Parvizi A, Poursaeidi E, Rahi A. Thermo-mechanical analysis of functionally graded wheel-mounted brake disk. J Mech Sci Technol, 2015, 29(10): 4197-4204

[16] Baron Saiz C, Ingrassia T, Nigrelli V, Ricotta V. Thermal stress analysis of different full and ventilated disc brakes. Frat. ed Integrita Strutt., 2015, 9(34): 608-621.

[17] Yevtushenko A, Kuciej M, Grzes P, Wasilewski P. Comparative analysis of temperature fields in railway solid and ventilated brake discs. Materials (Basel), 2021, 14(24): 7804

[18] Missori S, Sili A. Optimizing Proportions of Railway Brake Discs by Temperature Transients Evaluation. Proc Inst Mech Eng Part D Transp Eng, 1988, 202(2): 91-99

[19] Duzgun M. Investigation of thermo-structural behaviors of different ventilation applications on brake discs. J Mech Sci Technol, 2012, 26(1): 235-240

[20] Ansys inc (2018) ANSYS mechanical APDL element reference, In: Chapter 2: Element Classifications, Release 19, vol. 15317, no. November, Canonsburg: Southpointe 2600 ANSYS Drive, PA 15317, p. 9.

[21] Yu L, Jiang Y, Lu S, Ru H, Fang M. FEM for brake discs of SiC 3D continuous ceramic reinforced 7075 Aluminum alloy for CRH3 trains applying Emergency Braking. Appl Mech Mater, 2012, 120: 51-55

[22] Jiguang C, Fei G. Temperature field and thermal stress analyses of high-speed train brake disc under pad variations. Open Mech. Eng. J., 2015, 9(1): 371-378

[23] Luo Z, Zuo J. Conjugate heat transfer study on a ventilated disc of high-speed trains during braking. J Mech Sci Technol, 2014, 28(5): 1887-1897

[24] Grzes P, Oliferuk W, Adamowicz A, Kochanowski K, Wasilewski P, Yevtushenko AA. The numerical-experimental scheme for the analysis of temperature field in a pad-disc braking system of a railway vehicle at single braking. Int Commun Heat Mass Transf, 2016, 75: 1-6

[25] Rashid A. Overview of disc brakes and related phenomena - A review. Int J Veh Noise Vib, 2014, 10(4): 257-301

[26] Ouyang H, Abu-Bakar AR, Li L. A combined analysis of heat conduction, contact pressure and transient vibration of a disk brake. Int J Veh Des, 2009, 51(1–2): 190-206

[27] Belhocine A, Bouchetara M. Thermal-mechanical coupled analysis of a brake disk rotor. J Fail Anal Prev, 2013, 13(2): 167-176

[28] Belhocine A, Abu Bakar AR, Bouchetara M. Thermal and structural analysis of disc brake assembly during single stop braking event. Aust J Mech Eng, 2016, 14(1): 26-38

[29] Nong W, Gao F, Fu R, Yu Q. On structure function and the temperature and the thermal stress of brake discs. Appl Mech Mater, 2011, 80–81: 521-526

[30] Ansys inc (2018) ANSYS mechanical APDL command reference. In: N Commands, Release 19., no. August, Canonsburg: Southpointe 2600 ANSYS Drive, PA 15317, 2018, p. 1022.

[31] Ansys inc (2018) ANSYS mechanical APDL basic analysis guide, In: Chapter 3: Loading, Release 19., vol. 15317, no. November, Canonsburg: Southpointe 2600 ANSYS Drive, PA 15317, p. 36.

[32] Cho SK, Choi JH, Lee YM, Seok CS. Life evaluation of a disk brake of railway vehicles considering pressure distributions at a frictional surface”. Key Eng Mater, 2007, 353–358(PART 1): 303-306

[33] Wang GS, Fu R, Zhao L. Numerical modeling and simulation analysis of temperature field of disc brake on trains. Adv Mater Res, 2011, 199–200: 1492-1495.

[34] Wang Z, Han J, Liu X, Li Z, Yang Z, Chen E (2019) Temperature evolution of the train brake disc during high-speed braking, Adv Mech Eng, 11(1), 2019.

[35] Nong W, Gao F, Fu R, Han X. Investigation of friction temperature in railway disc brake. Adv Mater Res, 2012, 479–481: 202-206

[36] Belhocine A. Wan Omar WZ (2016) Stress analysis of automotive ventilate d disc brake rotor and pads using finite element method. Int J Multiphys, 2016, 10(1): 75-97.

[37] Fermér M. Brake discs for passenger trains—a theoretical and experimental comparison of temperatures and stresses in solid and ventilated discs. Proc Inst Mech Eng Part F J Rail Rapid Transit, 1992, 206(1): 37-46