Simulation and sensitivity analysis of wear on the automotive brake pad |
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| Affiliation: | 1. Laboratory of Tribology, Universidade Federal do Rio Grande do Sul, Sarmento Leite, 425, Porto Alegre 90050-170, Brazil;2. Laboratory of Design and Material Selection (LdSM), Universidade Federal do Rio Grande do Sul, Osvaldo Aranha, 99, Porto Alegre 90035-190, Brazil;1. University of Ljubljana, Faculty of Mechanical Engineering, Laboratory for Tribology and Interface Nanotechnology, Bogišičeva 8, 1000 Ljubljana, Slovenia;2. Iceland GeoSurvey – ISOR, Grensasvegur 9, 108 Reykjavik, Iceland;3. Malmsteypa Thorgrims Jonssonar ehf., Midhraun 6, 210 Gardabaer, Iceland;4. Luxembourg Institute of Science and Technology, Materials Research and Technology Department, 41 rue du Brill, L-4422 Belavux, Luxembourg;1. University of Kocaeli, Hereke Vocational School, Machine and Metal Technologies, Kocaeli, Turkey;2. Faculty of Engineering, Department of Mechanical Engineering, Düzce University, Düzce, Turkey;3. HİPAŞ Hydraulics Industry and Commercial, İstanbul, Turkey;1. Dipartmento di Ingegneria Industriale, Università di Trento, Via Sommarive 9, 38122 Trento, Italy;2. Brembo S.p.A., via Europa, 2, 24040 Stezzano (Bg), Italy;1. Faculty of Electric and Mechanical Engineering, Universidad Veracruzana, Poza Rica de Hidalgo, Veracruz, Mexico;2. Facultad de Ciencias Químicas, Universidad Veracruzana, Poza Rica de Hidalgo, Veracruz, Mexico;3. Centro de Nanociencias y Micro y Nanotecnologías, Unidad Profesional “Adolfo López Mateos”, IPN, Luis Enrique Erro S/N, Zacatenco, C.P. 07738 México City, D.F., Mexico;4. Instituto Politécnico Nacional, SEPI, ESIME, Unidad Profesional “Adolfo López Mateos” Tribology Group, Mechanical Engineering Department, Mexico |
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| Abstract: | In this paper, an algorithm is proposed for finite element simulation of wear employing the Archard's wear equation. To evaluate the accuracy of a FE model, an experimental test is performed on a standard-sized pin, made of a known brake pad. Comparison of worn masses, obtained by experimental and numerical approaches shows good accuracy of the developed algorithm. As the next step, passenger car single-piston and double-piston brake pad wear cases are simulated using the proposed algorithm. The rotor/pad contact area and worn mass are compared between the two cases. It is shown that usage of a double-piston brake pad over a single-piston one, can improve brake performance. The Taguchi Method with an orthogonal array L9 is then applied to optimize the design parameters, meaning maximization of the ``contact area'' and minimization of the ``worn mass''. The ANOVA method is also used for evaluating the impact of each design parameter on desired outputs. It is shown that the contact area is most likely to be affected by back plate thickness, while the worn mass is more sensitive to the diameter of the piston, closer to the leading edge of the pad. |
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