Investigation of layered brake pad by finite element method in static and dynamic loading conditions

In addition to ensuring the operating conditions of dynamic systems, braking systems are required to ensure that they slow down and stop safely when necessary. Brake systems are exposed to high thermal and mechanical stresses in a short period of time during working conditions. In this thesis, mechanical and thermal properties of brake and disc interaction have been examined by using finite element method. In addition to the static condition, dynamic conditions were taken into consideration. Firstly, sensitivity of finite element model was examined. Within the scope of the thesis, 4 layered rectangular and 2 layered crescent brakes with different materials in each layer are modeled and 0.05 MPa, 0.1 MPa and 0.2 MPa braking pressure is applied to brake pad for contact with the iron disc, which is rotating at a variable speed between 0 and 599.98 rpm. Also, the friction coefficient on the disc and pad contact surface was changed to be 0.2, 0.25 and 0.3. Temperature and Von-Mises stress values were taken from the points determined on pad and disc and interpreted. Iron material is defined as disc material, aluminum 2014-T6, brass, copper and titanium alloy 4V are defined as pad. Considering the results, it was observed that a high and irregular temperature was formed due to friction. pad surface is hotter than disk surface. Increasing braking pressure and coefficient of friction predominantly increase stress and temperatures. Thermal imbalance was determined in the results of 0.3 friction coefficient. Except for the contact layer, the temperature was not effective in the other layers of the pad. Copper-aluminum layered material has been determined as the most suitable considering both pad and disc stresses.