SUPR
A coupled FEM model of mechanical-thermo-fluid temperature prediction of rail vehicle brake disc
Dnr:

NAISS 2023/5-559

Type:

NAISS Medium Compute

Principal Investigator:

Sebastian Stichel

Affiliation:

Kungliga Tekniska högskolan

Start Date:

2023-12-21

End Date:

2024-07-01

Primary Classification:

20301: Applied Mechanics

Webpage:

Allocation

Abstract

This research focuses on developing a Finite Element Method (FEM) model to simulate the temperature development of a rail vehicle brake disc during braking. The goal is to accurately capture the complex interplay of contact mechanics, heat transfer, and fluid mechanics involved in the braking process. Here is a breakdown of the key aspects of the research: Background: Rail vehicles are evolving for higher speed and axle load, necessitating robust brake systems. The disc brake is a crucial mechanical brake system, converting kinetic energy into heat during braking. High brake disc temperature can lead to reduced friction and thermal stress, causing cracks. Challenges: Experimental investigation of brake systems is complex, leading to a preference for numerical studies. Existing methods include simple analytical solutions and computationally heavy commercial FEM software. Objective: Develop a new FEM model that balances accuracy and computational efficiency for simulating brake disc temperature during braking. Methodology: Derive partial differential equations for brake-related phenomena, encompassing contact mechanics, heat transfer, and fluid mechanics. Consider friction-generated heat instead of applied heat flux on the contact surface. Include heat conduction, convection, and radiation in the analysis. Account for airflow around the brake to determine the heat convection coefficient. Choose appropriate basis functions and assemble mass and stiffness matrices along with the load vector. Simulation and Validation: Compare simulation results, specifically temperature distributions, with analytical solutions and commercial FEM results. Highlight that the developed FEM model is more accurate than analytical solutions and faster than using commercial FEM software. Future Research Opportunities: Suggest that the validated FEM model can be used for more advanced research. Propose potential research directions, such as sensitivity analysis of railway brake disc temperature development and implementing adaptive meshing to reduce computation time. In summary, the research introduces a novel FEM model that effectively simulates the temperature development of rail vehicle brake discs during braking. The methodology and results suggest that this model offers a balance between accuracy and computational efficiency, opening avenues for further research in the field.