Skip to main content
SpringerLink
Log in

Optimal location of brake pad for reduction of temperature deviation on brake disc during high-energy braking

  • Original Article
  • Published:
Journal of Mechanical Science and Technology Aims and scope Submit manuscript

Abstract

During the braking process, frictional heat generated between a disc and a pad can lead to high temperatures. The location of friction blocks on the brake pad can lead directly to differences in friction contact time and friction speed at each point on the brake disc surface, this can lead to non-uniform temperature distribution on the brake disc surface. In this paper, the optimum design for friction blocks on a brake pad is investigated using the design of experiments (DOE) of Taguchi approach and response surface method (RSM) with an aim to minimize the deviation in the rate of friction heating in each area along the radial direction of brake disc. 18 design variables on 2 levels are adjusted. A table of orthogonal arrays, L32 (218), is used. Finite element analysis (FEA) is performed to analyze the mean squared error (MSE) values in the temperature deviations from frictional heat, the disc’s thermo-mechanical characteristics are taken into account. Analysis of variance (ANOVA) is carried out using the data gathered from the DOE stage, we find 7 significant factors among the design variables. A meta-model using RSM is proposed for reduction of temperature deviations over the brake disc. An optimized brake pad is analyzed in terms of the temperature and thermal stress imparted on the brake disc, this optimized pad is then compared with the original pad. The maximum temperatures of the optimized pad and original pad were 399.8 °C and 480.6 °C, respectively. The thermal stress of the optimized pad and original pad were 640.4 MPa and 721.4 MPa, respectively. In the optimized model, the size of the hot band on the disc is larger than that from the original model, so the thermal stress distribution on the disc is smaller. Finally, the optimized pad was found to give significant performance benefits with a 16.8 % decrease in maximum temperature and 11.2 % decrease in thermal stress.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

Abbreviations

P p :

Density of pad

C p :

Specific heat of pad

k p :

Thermal conductivity of pad

P d :

Density of disc

C d :

Specific heat of disc

k d :

Thermal conductivity of disc

k a :

Thermal conductivity of air

D :

Outer diameter of disc

R e :

Reynolds number

p a :

Density of air

v :

Velocity of railway vehicle

p p :

Density of pad

d :

Outer diameter of disc

References

  1. G. S. Wang and R. Fu, Impact of brake pad structure on temperature and stress fields of brake disc, Advances in Materials Science and Engineering (2013).

  2. J. H. Kim, A study on the mechanical properties of the braking disc due to the temperature change (1), Journal of the Korea Society for Railway, 8(3) (2005) 222–227.

    Google Scholar 

  3. S. H. Lee, Y. K. Kim, S. W. Kim and J. B. Park, Braking performance analysis and inspection of high speed train, Proceedings of the Korean Society for Noise Vibration Engineering Spring Conference (2006) 1–7.

  4. S. W. Kim, Y. G. Kim and K. H. Kim, A study on the establishment of disc braking force patter to reduce the wear mass of pad, Proceedings of the Korean Society for Railway Spring Conference (2007) 32–37.

  5. S. P. Jung, A study on loosening of bolts tightened in composite structure, Ph.D. Dissertation, Ajou University (2010).

  6. B. C. Goo, A study on the effect of parameters on the temperature distribution of brake discs, Proceedings of the Korean Society for Railway Spring Conference (2007) 7–12.

  7. J. H. Kim, B. C. Goo and C. S. Suk, A study on the temperature change of braking disc and thermal conductivity during the service, Journal of the Korea Society for Railway, 10(6) (2007) 665–669.

    Google Scholar 

  8. J. H. Yoo and S. H. Hahn, Optimal design of a disk-brake considering the eigen-frequency, Proceedings of the Korean Society for Noise and Vibration Engineering Fall Conference (2003) 655–659.

  9. J. T. Park and N. S. Choi, Robust design of the disc brake pad shape for reduction of uneven wear, Transaction of the Korean Society of Automotive Engineers, 20(1) (2012) 77–87.

    Article  Google Scholar 

  10. B. C. Goo and I. K. Na, Topology optimization of railway brake pad by contact analysis, Journal of The Korean Society of Tribologists and Lubrication Engineers, 30(3) (2014) 177–182.

    Article  Google Scholar 

  11. N. Benseddiq, D. Weichert, J. Seidermann and M. Minet, Optimization of design of railway disc brake pads, Proceedings of the Institution of Mechanical Engineers, Part F: Journal of Rail and Rapid Transit (1996) 51–61.

  12. H. J. Cho and C. D. Cho, A study of thermal and mechanical behavior for the optimal design of automotive disc brakes, Proceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering (2008) 895–915.

  13. F. Ficici, M. Durat and M. Kapsiz, Optimization of tribological parameters for a brake pad using Taguchi design method, Journal of the Brazilian Society of Mechanical Sciences and Engineering, 36 (2014) 653–659.

    Article  Google Scholar 

  14. M. Nouby, D. Mathivanan and K. Srinivasan, A combined approach of complex eigenvalue analysis and design of experiments (DOE) to study disc brake squeal, International Journal of Engineering, Science and Technology, 1(1) (2009) 254–271.

    Google Scholar 

  15. Y. K. Hu, S. Mahajan and K. Zhang, Brake squeal DOE using nonlinear transient analysis, SAE Transactions, 108 (1999) 2748–2755.

    Google Scholar 

  16. N. M. Ghazaly and W. F. Faris, Optimal design of a brake pad for squeal noise reduction using response surface methodology, International Journal of Vehicle Noise and Vibration, 8(2) (2012) 125–135.

    Article  Google Scholar 

  17. H. Lü and D. Yu, Optimization design of a disc brake system with hybrid uncertainties, Advances in Engineering Software, 98 (2016) 112–122.

    Article  Google Scholar 

  18. H. R. Hong, M. S. Kim, H. Y. Lee, I. S. Jo, N. T. Jeong, H. U. Moon, M. W. Suh and J. H. Lee, A study on an analysis model for the thermo-mechanical behavior of a solid disc brake for rapid transit railway vehicles, Journal of Mechanical Science and Technology, 32(7) (2018) 3223–3231.

    Article  Google Scholar 

  19. H. R. Hong, M. S. Kim, H. Y. Lee, N. T. Jeong, H. U. Moon, E. S. Lee, H. M. Kim, M. W. Suh, J. D. Chung and J. H. Lee, The thermo-mechanical behavior of brake discs for high-speed railway vehicles, Journal of Mechanical Science and Technology, 33(4) (2019) 1711–1721.

    Article  Google Scholar 

  20. R. Limpert, Brake Design, and Safety, Second Ed., Warrendale, PA: Science of Automotive Engineers Inc., USA (1992).

    Google Scholar 

  21. P. Hwang and X. Wu, Investigation of temperature and thermal stress in ventilated disc brake based on 3D thermomechanical coupling model, Journal of Mechanical Sciences and Technology, 24 (2010) 81–84.

    Article  Google Scholar 

  22. P. Hwang, X. Wu and Y. B. Jeon, Repeated brake temperature analysis of ventilated brake disc on the downhill road, SAE Technical Paper (2008).

  23. P. Hwang, H. C. Seo and X. Wu, Temperature field and thermal stress simulation of solid brake disc based on three-dimensional model, Journal of the Korean Society of Tribologists and Lubrication Engineers, 26(1) (2010) 31–36.

    Google Scholar 

  24. C. S. Chung, M. I. Choi, Y. I. Lee and H. K. Kim, A study on thermal cracking of ventilated brake disk of a car using fem analysis, Journal of the Korean Society of Tribologists and Lubrication Engineers, 21(2) (2005) 63–70.

    Google Scholar 

  25. UIC CODE 541-3, Brakes-Disc Brakes and their Application-General Conditions for the Approval of Brake Pads, 7th Eds., UIC (2010).

  26. D. O. Kang, Y. H. Woo and K. U. Cha, Barrel rifling shape optimization by using design of experiment approach, Transaction of the Korean Society of Automotive Engineers, 36(8) (2012) 897–904.

    Article  Google Scholar 

  27. A. S. Hedayat, N. J. A. Sloane and J. Stufken, Orthogonal Arrays: Theory and Applications, Springer (1999).

  28. P. W. M. John, Statistical Design and Analysis of Experiments, Society for Industrial and Applied Mathematics (1998).

  29. R. H. Myers and D. C. Montgomery, Response Surface Methodology, Wiley Series in Probability and Statistics (1995).

  30. K. H. Suh, H. K. Min and I. B. Chyun, Optimum design of front toe angle using design of experiment and dynamic simulation for evaluation of handling performances, Transaction of the Korean Society of Automotive Engineers, 8(2) (2000) 120–128.

    Google Scholar 

  31. K. H. Lee, I. S. Eom, G. J. Park and W. I. Lee, Robust design for unconstrained optimization problems using the taguchi method, AIAA Journal, 34(5) (1996) 1059–1063.

    Article  MATH  Google Scholar 

  32. W. S. Kwon, K. S. Park, Y. H. Kim and I. D. Kim, Design of steering system considering interaction effects in dicrete design space, Proceedings of the Korean Society for Noise and Vibration Engineering Spring Conference (2006) 673–679.

  33. G. J. Park, Y. S. Park and S. H. Lee, Comparisons of the direct and approximation method in structural optimization, Proceedings of Pan-Pacific Conference for Computer Engineering (1993).

  34. E. S. Kim, I. S. Lee and B. M. Kim, Optimum design of washing machine flange using design of experiment, Transaction of the Korean Society of Automotive Engineers, 31(5) (2007) 601–608.

    Google Scholar 

  35. S. M. Lee, Design of Experiment on the Center of Example, ERETEC INC (2005).

  36. F. Lei, X. Lv, J. Fang, G. Sun and Q. Li, Multiobjective discrete optimization using the TOPSIS and entropy method for protection of pedestrian lower extremity, Thin-walled Structures, 152 (2020) 106349.

    Article  Google Scholar 

  37. I. K. Bang, D. S. Han, G. J. Han and K. H. Lee, Structural optimization for a jaw using the kriging model, Journal of Mechanical Science and Technology, 22(9) (2008) 1651–1659.

    Article  Google Scholar 

  38. J. H. Choi and N. C. Kang, Run-flat tire optimization using response surface method and genetic algorithm, Transaction of the Korean Society of Automotive Engineers, 25(4) (2015) 247–254.

    Google Scholar 

  39. X. Song, G. Sun, G. Li, W. Gao and Q. Li, Crashworthiness optimization of foam-filled tapered thin-walled structure using multiple surrogate models, Struct. Multidisc. Optim., 47 (2013) 221–231.

    Article  MathSciNet  MATH  Google Scholar 

  40. Z. Wang, X. Jin, Q. Li and G. Sun, On crashworthiness design of hybrid metal-composite structures, International Journal of Mechanical Sciences, 171 (2020) 105380.

    Article  Google Scholar 

  41. J. S. Arora, Introduction to Optimum Design, Third Ed., Elsevier Inc, USA (2012).

    Google Scholar 

Download references

Acknowledgments

This research was supported by a grant from R&D Program of the Korea Railroad Research Institute, Republic of Korea.

Author information

Authors and Affiliations

  1. Machinery & Robotics Research Team, Daegu Mechatronics & Materials Institute, Daegu, 42714, Korea

    Heerok Hong

  2. School of Mechanical Engineering, Sungkyunkwan University, Gyeonggi, 440-746, Korea

    Gyeongpil Kim, Jaesik Kim, Dasom Lee & Myungwon Suh

  3. Urban Transit Research Team, Korea Railroad Research Institute, Gyeonggi, 437-757, Korea

    Hoyong Lee & Minsoo Kim

  4. Department of Automotive Engineering, Osan University, Gyeonggi, 447-749, Korea

    Junghwan Lee

Authors
  1. Heerok Hong
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Gyeongpil Kim
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Hoyong Lee
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Jaesik Kim
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Dasom Lee
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Minsoo Kim
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Myungwon Suh
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Junghwan Lee
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Hoyong Lee.

Additional information

Recommended by Editor Seungjae Min

Hee-Rok Hong received the B.S. and M.S. degrees in mechanical engineering from Gyeonggi University in 2013, 2015, respectively. He received the Ph.D. degree in mechanical engineering from Sungkyunkwan University in 2020. He is currently a Senior Researcher of Daegu Mechatronics & Materials Institute. His research areas include the design and modeling, structure analysis, and optimum design.

Ho-Yong Lee received the Ph.D. degree in mechanical design engineering from Sungkyunkwan University in 2005. He is currently a Senior Researcher of Korea Railroad Research Institute. His research areas include the structure analysis, fatigue/fracture mechanics, system reliability, and brake system.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Hong, H., Kim, G., Lee, H. et al. Optimal location of brake pad for reduction of temperature deviation on brake disc during high-energy braking. J Mech Sci Technol 35, 1109–1120 (2021). https://doi.org/10.1007/s12206-021-0224-x

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12206-021-0224-x

Keywords

Search

Navigation