Transcript Document

CONTENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
Introduction
Objective and scopes
Project flow
Literature review
Previous work
Contact analysis
Result
Structural modification
Conclusion
1. INTRODUCTION
• Contact analysis is normally performed on brake
assembly to study the pressure distribution and the
contact area.
• Significant of contact analysis are to investigate the
effect of contact problem to the wear, thermal and
squeal.
• Only Finite Element Method are able to use to perform
contact analysis both static and dynamic conditions.
content
2. OBJECTIVE
“TO DETERMINE CONTACT PRESSURE DISTRIBUTION
AND CONTACT AREA OF A DRUM BRAKE ASSEMBLY
USING FINITE ELEMENT METHOD”
SCOPES




Develop a Finite Element model of drum brake.
Validate the Finite Element model against experimental
result using modal analysis.
Perform contact analysis using a commercial
Finite Element (FE) software package.
Propose structural modification method in order to
determine uniform contact pressure distribution and
higher contact area.
content
3. PROJECT FLOW
SMJ 5912
START
SMJ 5924
Generate FE model
Run modal analysis
START
Compare Modal
Analysis Result
Between
Experimental and
FE Method
Perform
Contact Analysis using
validated model
Error not
exceed than
5%
Purpose
structural modification
No
Yes
FINISH
FINISH
content
4. LITERATURE REVIEW
The FE model validated by using
modal analysis
Contact pressure at leading shoe are
more higher than trailing shoe.
Parameters that can influence
contact analysis are:
Coefficient of friction
Material properties
Actuation pressure
Rotation speed
Installation gap
Figure : Contact pressure distribution for leading
and trailing shoes H-i Kang (2002)
content
5. PREVIOUS WORK
(PSM 1)
Three components of drum brake
assembly are generated (Drum, leading
shoe and trailing shoe)
FE model are validated using the
experimental data (Modal analysis)
Material properties for the model are
listed below
DRUM
BRAKE SHOE BODY
LINING
Density (kg/m3)
7673
8762
2638
Young's modulus (GPa)
104
250
3.1
Poisson's ratio
0.3
0.3
0.3
FE model
Components
Types of element
No. of
elements
No.
nodes
Drum
Linear hexahedral
elements
(C3D8)
7546
13578
Leading
shoe
Linear hexahedral
elements
(C3D8)
Linear wedge
element type (C3D6)
1023
2776
Trailing
shoe
Linear hexahedral
elements
(C3D8)
Linear wedge
element type (C3D6)
1130
2042
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6. CONTACT ANALYSIS
Surface-to-surface contact interaction
The drum surface are set as master
surface
The lining surface are set as slave
surface
Figure : Result obtain from FE software
CONTACT ANALYSIS
6 Parameters were used to study the influence
to contact analysis
1. Test condition
2. Coefficient of friction
3. Actuation pressure
4. Material properties (lining)
5. Material properties (brake shoe body)
6. Installation gap
content
CONTACT AREA WITH DIFFERENT
TEST CONDITION
Contact area for different drum condition
100
90
Contact area (%)
80
70
Leading
60
Trailing
50
40
30
20
10
0
Static
Dynamic
Test condition
Contact area 5.5% larger for dynamic test condition for leading shoe
Contact area are 27.1% smaller for trailing shoe.
CONTACT PRESSURE DISTRIBUTION FOR
LEADING SHOE
Contact Pressure distribution at rotation = 6rad/sec
(Leading)
Contact Pressure distribution at static condition
(Leading)
Contact Pressure (Pa)
6.0E+05
Contact Pressure (Pa)
6.0E+05
5.0E+05
4.0E+05
3.0E+05
2.0E+05
1.0E+05
0.0E+00
5.0E+05
Actuation side
4.0E+05
3.0E+05
0
11
22
32
43
54
Angular Position (o)
2.0E+05
65
75
Lining width
86
1.0E+05
97
Dynamic
0.0E+00
Actuation side
0
11
22
32
43
54
65
Angular position (o)
75
Lining width
86
97
Static
Abutment side
Abutment side
CONTACT PRESSURE DISTRIBUTION FOR
TRAILING SHOE
Trailing shoe step 2 (2-1)
5.0E+05
4.0E+05
3.0E+05
2.0E+05
Lining width
92
102
2.0E+05
Dynamic
1.0E+05
82
Lining width
102
92
Angular position (o)
72
61
51
41
0.0E+00
Actuation side
82
Angular Position (o)
3.0E+05
72
4.0E+05
61
Actuation side
51
5.0E+05
41
0.0E+00
0
10
20
31
1.0E+05
6.0E+05
0
10
20
31
Contact Pressure (Pa)
Contact Pressure distribution at static condition
(Leading)
Contact Pressure (Pa)
6.0E+05
Static
Abutment side
Abutment side
CONTACT AREA WITH DIFFERENT
COEFFICIENT OF FRICTION
Contact area with different coefficient of friction
100
90
Contact area (%)
80
70
Leading
60
50
Trailing
40
30
20
10
0
0.20
0.25
0.30
0.35
0.40
Coefficient of Friction
The higher value coefficient of friction, the lower contact area.
CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT
COEFFICIENT OF FRICTION
(LEADING)
Contact Pressure distribution
with different value of coefficient of friction
(Leading)
6.0E+05
μ
0.20
Contact Pressure (Pa)
5.0E+05
0.25
0.30
0.35
4.0E+05
0.40
3.0E+05
2.0E+05
1.0E+05
0.0E+00
0
Actuation side
20
40
60
Angular position (O)
80
100
Abutment side
CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT
COEFFICIENT OF FRICTION
Contact Pressure distribution with different value of coefficient of friction
(TRAILING)
(Trailing)
6.0E+05
μ
0.20
5.0E+05
Contact Pressure (Pa)
0.25
0.30
4.0E+05
0.35
0.40
3.0E+05
2.0E+05
1.0E+05
0.0E+00
0
Actuation
side
20
40
60
Angular position (O)
80
100
Abutment side
CONTACT AREA WITH DIFFERENT
Contact
area with different actuation
pressure
ACTUATION
PRESSURE
100
95
Contact area (%)
90
85
80
Leading
75
Trailing
70
65
60
55
50
2.0
2.5
3.0
3.5
4.0
Actuation Pressure (Mpa)
Contact area unchained for both shoes when different
actuation pressure are applied.
85.7% for leading and 64.2% for trailing
CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT
ACTUATION PRESSURE
Contact Pressure Distribution with different actuation pressure
(Leading)
(LEADING)
9.0E+05
Pressure Distribution (Pa)
8.0E+05
2 MPa
2.5MPa
3 MPa
3.5 MPa
4 MPa
7.0E+05
6.0E+05
5.0E+05
4.0E+05
3.0E+05
2.0E+05
1.0E+05
0.0E+00
0
Actuation side
20
40
60
80
o
Angular position ( )
100
Abutment side
CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT
ACTUATION PRESSURE
(TRAILING)
Contact Pressure distribution with different actuation pressure
(Trailing)
9.0E+05
Pressure Distribution (Pa)
8.0E+05
7.0E+05
2 MPa
2.5MPa
3 MPa
3.5 MPa
4 MPa
6.0E+05
5.0E+05
4.0E+05
3.0E+05
2.0E+05
1.0E+05
0.0E+00
0
Actuation side
20
40
60
80
o
Angular position ( )
100
Abutment side
CONTACT AREA WITH DIFFERENT
MATERIAL PROPERTIES
(LINING)
Contact area with different
modulus of elasticity (lining)
100
95
85
80
Leading
75
70
Trailing
65
60
15%
10%
5%
baseline
-5%
50
-10%
55
-15%
Contact area (%)
90
Variation (%)
The actual Elastic properties for lining is 3.10GPa
CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT
MATERIAL PROPERTIES
Contact Pressure distribution with different modulus of elasticity
(LEADING)
(Leading lining)
6.0E+05
-15%
-10%
-5%
baseline
5%
10%
15%
Contact Preessure (Pa)
5.0E+05
4.0E+05
3.0E+05
2.0E+05
1.0E+05
0.0E+00
0
8
Actuation side
16
24
32
40
48
57
65
Angular position (o)
73
81
89
97
105
Abutment side
CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT
MATERIAL PROPERTIES
(TRAILING)
Contact Pressure distribution
with different modulus of elasticity
(Trailing lining)
6.0E+05
-15%
-10%
-5%
baseline
5%
10%
15%
Contact Preessure (Pa)
5.0E+05
4.0E+05
3.0E+05
2.0E+05
1.0E+05
0.0E+00
0
8
Actuation side
16
24
32
40
48
57
65
73
o
Angular position ( )
81
89
97
105
Abutment side
CONTACT AREA WITH DIFFERENT
MATERIAL PROPERTIES
Contact area with different elastic modulus
(BRAKE SHOE BODY)
100
95
Contact area (%)
90
85
80
75
Leading
70
Trailing
65
60
15%
10%
5%
baseline
-5%
-10%
50
-15%
55
Variation (%)
The actual Elastic properties for brake shoe body is 250GPa
CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT
MATERIAL
PROPERTIES
Contact Pressure
distribution
with different modulus of elasticity
(Leading shoe body)
(LEADING)
6.0E+05
Contact Preessure (Pa)
5.0E+05
-15%
-10%
-5%
baseline
5%
10%
15%
4.0E+05
3.0E+05
2.0E+05
1.0E+05
0.0E+00
0
10
Actuation side
20
31
41
51
61
o
Angular position ( )
72
82
92
Abutment side
CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT
MATERIAL PROPERTIES
Contact Pressure distribution
with different modulus of elasticity
(TRAILING)
(Leading shoe body)
6.0E+05
Contact Preessure (Pa)
5.0E+05
-15%
-10%
-5%
baseline
5%
10%
15%
4.0E+05
3.0E+05
2.0E+05
1.0E+05
0.0E+00
0
10
Actuation side
20
31
41
51
61
Angular position (o)
72
82
92
102
Abutment side
CONTACT AREA WITH DIFFERENT
INSTALLATION
GAP gap
Contact
area with different installation
100
95
85
80
Leading
75
Trailing
70
65
60
55
2.0. mm
1.5 mm
1.0 mm
0.5 mm
50
0 mm
Contact area (%)
90
Installation gap
Highest area for leading shoe at 2mm gap (85.8%)
Highest area for trailing at 0.5mm gap (65.0%)
CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT
Contact Pressure distribution by varying the installation gap
INSTALLATION
GAP
(Leading)
(LEADING)
6.0E+05
0.5 mm
Contact Pressure (Pa)
5.0E+05
1.0 mm
1.5 mm
2.0 mm
4.0E+05
0 mm
3.0E+05
2.0E+05
1.0E+05
0.0E+00
0
Actuation side
20
40
60
80
o
Angular position ( )
100
Abutment side
CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT
INSTALLATION GAP
Contact Pressure distribution with different installation gap
(Leading)
(TRAILING)
6.0E+05
5.0E+05
0.5 mm
Contact Pressure (Pa)
1.0 mm
1.5 mm
4.0E+05
2.0 mm
0 mm
3.0E+05
2.0E+05
1.0E+05
0.0E+00
0
Actuation side
20
40
60
80
o
Angular position ( )
100
Abutment side
content
Overall Results
PARAMETER
CONTACT
AREA
CONTACT
PRESSURE DISTRIBUTION
COEFFICIENT OF FRICTION
VARY
VARY
NO
VARY
E LINING
VARY
VARY
E BRAKE SHOE BODY
VARY
VARY
INSTALLATION GAP
VARY
VARY
ACTUATION PRESSURE
content
STRUCTURAL MODIFICATION
Structural modification done to
“Obtain more uniform pressure distribution by seeking greater contact
area and lower pressure”
Greater contact area and uniform pressure distribution can reduce the
uneven wear and squeal.
Structural modification done by changing the current geometry
MODEL 1
: Adjust location for leading lining
MODEL 2
: Adjust location for trailing lining
MODEL 3
: Add more length for both shoe
MODEL 4
: Add thickness at shoe rib
MODEL 5
: Add thickness at shoe platform
STRUCTURAL MODIFICATION
(CTD)
Current Model
Model 1
Model 3
Model 4
Model 2
Model 5
CONTACT AREA
Contact area with different model
100
90
Contact area (%)
80
70
60
50
40
30
20
Model 5
Model 4
Model 3
Model 2
Current
0
Model 1
10
Figure :Contact area for different models
MODEL
SHOE
1
2
3
4
5
LEADING
3.8%
0
-1.1%
-5.4%
7.2%
TRAILING
-7.3%
-37%
-0.2%
-8.3%
1.7%
Comparison base on current model
MODEL 1
3-1 Trailing shoe
Contact Pressure (Pa)
6.0E+05
Leading shoe
6.0E+05
5.0E+05
Trailing
4.0E+05
3.0E+05
2.0E+05
1.0E+05
1.0E+05
Lining width
93
Angular Position (o)
82
2.0E+05
72
3.0E+05
62
4.0E+05
51
Actuation side
10
21
31
41
0
5.0E+05
Abutment side
82
72
Lining width
93
Angular Position (o)
62
Actuation side
51
0
0.0E+00
10
21
31
41
Contact Pressure (Pa)
0.0E+00
Leading
Abutment side
MODEL 2
Trailing shoe
Contact Pressure (Pa)
6.0E+05
Leading shoe 4-1
5.0E+05
4.0E+05
Trailing
3.0E+05
2.0E+05
1.0E+05
0.0E+00
93
83
0.0E+00
0
Actuation side
10
21
31
Lining width
Abutment side
41
52
o
Angular Position ( )
62
72
83
93
Abutment side
Leading
72
Angular Position (o)
1.0E+05
62
2.0E+05
52
Actuation side
3.0E+05
41
0
4.0E+05
10
21
31
Contact Pressure (Pa)
6.0E+05
5.0E+05
Lining width
MODEL 3
Trailing shoe 5-1
Contact Pressure (Pa)
6.0E+05
Leading shoe 5-1
5.0E+05
4.0E+05
Trailing
3.0E+05
2.0E+05
1.0E+05
0.0E+00
0.0E+00
94
84
73
63
52
42
31
21
10
Angular Position (o)
Leading
94
Lining width
Abutment side
0
Actuation side
84
1.0E+05
73
Angular Position (o)
63
2.0E+05
52
Actuation side
3.0E+05
42
0
4.0E+05
10
21
31
Contact Pressure (Pa)
6.0E+05
5.0E+05
Lining width
Abutment side
MODEL 4
Trailing shoe
Contact Pressure (Pa)
Leading
Lining width
102
92
82
61
71
o
Angular Position ( )
51
41
10
20
31
Actuation side
Abutment side
Lining width
102
92
82
71
Angular Position (o)
61
51
41
10
20
31
Actuation side
Trailing
0
1.0E+06
9.0E+05
8.0E+05
7.0E+05
6.0E+05
5.0E+05
4.0E+05
3.0E+05
2.0E+05
1.0E+05
0.0E+00
0
Contact Pressure (Pa)
1.0E+06
9.0E+05
8.0E+05
7.0E+05
6.0E+05
5.0E+05
4.0E+05
3.0E+05
2.0E+05
1.0E+05
0.0E+00
Leading
Abutment side
MODEL 5
Contact Pressure distribution at rotation = 6rad/sec
(T)
Contact Pressure distribution at rotation = 6rad/sec
l
5.0E+05
4.0E+05
4.0E+05
3.0E+05
2.0E+05
1.0E+05
102
94
Lining width
Abutment side
102
Lining width
94
86
79
71
Angular Position (o)
Trailing
86
Angular Position (o)
0.0E+00
79
1.0E+05
0
8
16
24
31
39
47
55
63
71
Actuation side
2.0E+05
Actuation side
5.0E+05
0.0E+00
3.0E+05
0
8
16
24
31
39
47
55
63
Contact Pressure (Pa)
6.0E+05
Contact Pressure (Pa)
6.0E+05
Abutment side
Leading
content
CONCLUSION
1. Only FE method are able to perform contact analysis
both static and dynamic conditions.
2. Maximum contact pressure occurs at the actuation side
for leading shoe and at the abutment side for trailing
shoe.
3. Parameters that can influence the contact properties are
coefficient of friction, material properties, actuation
pressure and installation gap.
4. Structural modification can improve the contact area and
pressure distribution.
THANK YOU