Thermal stress simulation and fatigue life of commercial vehicle disk brakes under emergency braking conditions

Commercial vehicle disk brakes operate at a high-temperature and in a heavy-load environment within the braking system. The primary cause of failure is the cracking of the brake disk. In order to study its fatigue damage and service life, a finite element model of disk brake fatigue life was established, and thermal stress coupling simulation analysis was carried out from a practical problem. Based on the temperature and stress fields of the brake disk under emergency braking conditions obtained from the simulation results, the effects of vehicle load, initial speed, temperature, and other factors on brake fatigue life are explored. The fatigue life of the hazardous node can be calculated using the Manson–Coffin model, and then the strain–life (ɛ–N) curve of the material can be fit at high temperature. The fatigue life of brake disks was predicted using the fatigue analysis software FE-SAFE and verified by testing. The results showed that the maximum stress on the surface of the disk brake was the same as the area of the minimum fatigue life, accurately analyzing the fatigue life of the region and predicting the location of fatigue cracks. The results of the research can provide a reference for the design of disk brake engineering and fatigue failure.