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Low and high cycle fatigue of automotive brake discs using coupled thermo-mechanical finite element analysis under thermal loading

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Abstract

To predict the thermal fatigue life and thermal stress phenomena of a brake disc, it is necessary to study the thermo-mechanical coupling effect in terms of braking conditions. Thermal fatigue stress of automotive brake discs was analyzed by using the coupled thermomechanical finite element (FE) simulation. The FE model was developed by considering the effect of conduction and convection heat transfer by frictional heat generation and film condition. Experimental boundary conditions of the brake dynamometer were applied to the simulation model. The structural stress due to the stress concentration effect on the bolt holes was also confirmed. The thermal fatigue life of the friction surface and the bolt holes was differently estimated depending on the influence of the stress amplitude. The strain-life relationship was used to predict thermal fatigue life in view of elastic and plastic deformation. The fatigue cycle ratio was also presented to calculate the fatigue life for different braking pressures.

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Authors and Affiliations

  1. School of Mechanical Engineering, Ajou University, Suwon, 443-749, Korea

    Myeong-Jae Han & Chul-Hyung Lee

  2. Department of Mechanical Engineering, Ajou University, Suwon, 443-749, Korea

    Tae-Won Park

  3. R&D Center, ILJIN Global, Seoul, 06157, Korea

    Seung-Pyo Lee

Authors
  1. Myeong-Jae Han
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  2. Chul-Hyung Lee
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  3. Tae-Won Park
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  4. Seung-Pyo Lee
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Corresponding author

Correspondence to Tae-Won Park.

Additional information

Recommended by Associate Editor Beomkeun Kim

Myeong-Jae Han received his B.S. in Mechanical Engineering from Ajou University in South Korea in 2016. He is currently a combined master’s and doctoral candidate at the Applied Mechanics Lab. at Ajou University. Mr. Han’s research interests are in the areas of flexible multi-body dynamics and computer aided engineering.

Tae-Won Park received his B.S. in Mechanical Engineering from Seoul National University. He then went on to receive his M.S. and Ph.D. degrees from the University of Iowa. Dr. Park is currently a Professor at the Department of Mechanical Engineering at Ajou University in Suwon, Korea.

Seung-Pyo Lee received his B.S., M.S., and Ph.D. in Mechanical Engineering from Hanyang University. Dr. Lee is currently a Director for ILJIN Global and his research interests are in the area of computer aided analysis.

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Han, MJ., Lee, CH., Park, TW. et al. Low and high cycle fatigue of automotive brake discs using coupled thermo-mechanical finite element analysis under thermal loading. J Mech Sci Technol 32, 5777–5784 (2018). https://doi.org/10.1007/s12206-018-1125-5

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  • DOI: https://doi.org/10.1007/s12206-018-1125-5

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