Finite element analysis (FEA) of frictional contact phenomenon on vehicle braking system

The braking phenomenon is an aspect of vehicle stopping performance where with kinetic energy due to the speed of the vehicle is transformed into thermal energy via the friction between the brake disk and its pads. The heat must then be dissipated into the surrounding structure and the airflow around the brake system. The frictional thermal field during the braking phase between the disk and the brake pads can lead to excessive temperatures. In our work, we presented numerical modeling using ANSYS software adapted in the finite element method, to follow the evolution of the global temperatures for the two types of brake disks, full and ventilated disk during braking scenario. Also, numerical simulation of the transient thermal and the static structural analysis were performed here sequentially, with coupled thermo-structural method. Numerical procedure of calculation relies on important steps such that the computational fluid dynamic (CFD) and thermal analysis have been well illustrated in 3D, showing the effects of heat distribution over the brake disk. This CFD approach helped in the calculation of the values of the heat transfer coefficients (h) that have been exploited in the 3D transient evolution of the brake disk temperatures. Three different brake disk materials were tested and comparative analysis of the results was conducted in order to derive the one with the best thermal behavior. The current numerical results were in good agreement with the previous experimental results available in literature. Finally, the resolution of the coupled thermomechanical model allows us to visualize other important results of this research, such as; the deformations, and the equivalent Von Mises stresses of the disk, as well as the contact pressure distribution on the brake pads. According to the results presented in this investigation, several conclusions can be drawn. The choice allowed us to deliver the excellent rotor design to ensure and guarantee the better braking performance of the vehicles.