Simulation analysis of brake disc temperature field and brake pad wear of high-speed train under wheel-rail excitation

doi:10.3785/j.issn.1006-754X.2023.03.103

Chinese Journal of Engineering Design

2023, Vol. 30

Issue (6): 753-762 DOI: 10.3785/j.issn.1006-754X.2023.03.103

Modeling, Simulation, Analysis and Decision

Simulation analysis of brake disc temperature field and brake pad wear of high-speed train under wheel-rail excitation

Haiyan ZHU^1,²(

),Jiachao DENG^1,²,Qian XIAO^1,²,Jie LI^1,²,Yong YI^1,²

^1.State Key Laboratory of Performance Monitoring and Protecting of Rail Transit Infrastructure, East China Jiaotong University, Nanchang 330013, China
^2.Key Laboratory of Conveyance Equipment Ministry of Education, East China Jiaotong University, Nanchang 330013, China

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Abstract

A high-speed train dynamics model was established to study the effect of wheel rail excitation on the temperature distribution of brake discs and the surface wear of brake pads. The vertical and lateral vibration amplitudes of the brake disc under emergency braking conditions were obtained through dynamic simulation. The amplitudes were introduced into the finite element model of the brake disc thermal-mechanical coupling established by the direct coupling method as input condition. The temperature variation law of each node in the radial, axial and circumferential of the brake disc was compared and analyzed under the condition of with or without wheel-rail excitation. The ALE (arbitrary Lagrangian-Eulerian) mesh adaptive processing was performed on the surface of the brake pad based on the finite element model of brake disc thermal-mechanical coupling, combined with Umeshmotion wear subroutine, the calculation of the surface wear depth of the brake pad was realized. The influence of with or without wheel-rail excitation on the wear depth of the surface of the brake pad was compared and analyzed. The simulation results show that compared with no wheel-rail excitation, the temperature of radial, axial and circumferential nodes of brake disc decreases under wheel-rail excitation, and the circumferential nodes reach the highest temperature at the same time, and the time for radial and axial nodes to reach the highest temperature is shortened. Under the wheel-rail excitation, the wear depth of each node in the radial and circumferential of the surface of the brake pad increases, which increases the wear of the brake pad surface and reduces the brake pad service life. The results of the research can provide some reference for more accurate prediction of the service life of the brake pad.

Key words： high-speed train wheel-rail excitation brake disc thermal-mechanical coupling temperature field wear

Received: 10 January 2023 Published: 02 January 2024

CLC:

U 270.35

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Cite this article:

Haiyan ZHU,Jiachao DENG,Qian XIAO,Jie LI,Yong YI. Simulation analysis of brake disc temperature field and brake pad wear of high-speed train under wheel-rail excitation. Chinese Journal of Engineering Design, 2023, 30(6): 753-762.

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https://www.zjujournals.com/gcsjxb/10.3785/j.issn.1006-754X.2023.03.103 OR https://www.zjujournals.com/gcsjxb/Y2023/V30/I6/753

轮轨激励下高速列车制动盘温度场及闸片磨损仿真分析

为了研究轮轨激励对制动盘温度场分布及闸片表面磨损的影响，建立了高速列车动力学模型。通过动力学仿真，得出紧急制动工况下制动盘垂向和横向振动幅值；将振幅作为输入条件，导入制动盘热-机耦合有限元模型，分析有、无轮轨激励时制动盘径向、轴向和周向各节点的温度变化规律。基于制动盘热-机耦合有限元模型，结合Umeshmotion磨损子程序，对闸片表面进行ALE车轮非线性临界速度网格自适应处理，实现闸片表面磨损深度的计算，并对比分析有、无轮轨激励对闸片表面磨损深度的影响。仿真结果表明：与无轮轨激励相比，在轮轨激励下制动盘径向、轴向和周向各节点温度降低，且周向各节点在同一时刻达到最高温度，径向和轴向各节点达到最高温度的时间缩短；闸片表面径向和周向各节点的磨损深度增大，加剧了闸片表面的磨损，减少其使用寿命。研究结果可以为更加精准地预测闸片使用寿命提供一定的参考。

关键词： 高速列车, 轮轨激励, 制动盘, 热机耦合, 温度场, 磨损

Fig.1 Dynamics model of high-speed train

Fig.2 Nonlinear critical speed of wheels

Fig.3 Variation curve of brake disc vibration amplitude with time

Table 1 Structure parameters of brake disc and pad

参数名称	制动盘	闸片
杨氏模量/ $P a$	$2 × 1011$	$2 × 1011$
泊松比	0.285	0.300
热传导系数/ $? W / (m ? K)$	61	74
热膨胀系数/ $K - 1$	$1.16 × 10 - 5$	$1.1 × 10 - 5$
比热/ $? J / (k g ? K)$	745	436

Table 2 Brake disc material parameters

Fig.4 3D model structure of brake disc and pad

Fig.5 Grid division of models of brake disc and brake pad

Fig.6 Cloud map of temperature distribution on surface of brake discs

Fig.7 Nodes distribution of brake disc in three directions

Fig.8 Variation curve of radial node temperature of brake disc with time

Fig.9 Variation curve of brake disc axial nodal temperature with time

Fig.10 Variation curve of brake disc circumferential node temperature with time

Fig.11 Adaptive grid area of ALE

Fig.12 Cloud map of wear distribution on brake pad surface

Fig.13 Node diagram of brake pad surface wear analysis

Fig.14 Wear depth of each node on surface of brake pad after braking is completed


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