1.introductionintroduction 2.objective and scopesobjective and scopes 3.project flowproject flow...
TRANSCRIPT
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1. Introduction2. Objective and scopes3. Project flow4. Literature review5. Previous work6. Contact analysis7. Result8. Structural modification9. Conclusion
CONTENTSCONTENTS
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1. INTRODUCTION1. 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
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“TO DETERMINE CONTACT PRESSURE DISTRIBUTION
AND CONTACT AREA OF A DRUM BRAKE ASSEMBLY
USING FINITE ELEMENT METHOD”
2. OBJECTIVE2. OBJECTIVE
SCOPESSCOPES
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
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3. PROJECT FLOW
Generate FE model
Run modal analysis
Compare Modal Analysis Result
BetweenExperimental and
FE Method
No
Yes
Error notexceed than
5%
START
FINISH
SMJ 5912
PerformContact Analysis using
validated model
Purposestructural modification
START
FINISH
SMJ 5924
content
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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
4. LITERATURE REVIEW4. LITERATURE REVIEW
Figure : Contact pressure distribution for leading and trailing shoes H-i Kang (2002) content
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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
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
5. PREVIOUS WORK(PSM 1)
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Components Types of element No. of elements
No. nodes
DrumLinear 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
content
FE modelFE model
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Surface-to-surface contact interaction
The drum surface are set as master surface
The lining surface are set as slave surface
6. CONTACT ANALYSIS
Figure : Result obtain from FE software
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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 ANALYSISCONTACT ANALYSIS
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0
10
20
30
40
50
60
70
80
90
100C
on
tact
are
a (%
)
Static Dynamic
Test condition
Contact area for different drum condition
Leading
Trailing
CONTACT AREA WITH DIFFERENTCONTACT AREA WITH DIFFERENTTEST CONDITIONTEST CONDITION
Contact area 5.5% larger for dynamic test condition for leading shoe
Contact area are 27.1% smaller for trailing shoe.
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011
2232
4354
6575
8697
0.0E+00
1.0E+05
2.0E+05
3.0E+05
4.0E+05
5.0E+05
6.0E+05
Co
nta
ct P
ress
ure
(P
a)
Angular position (o)
Contact Pressure distribution at static condition(Leading)
Actuation side
Abutment side
Lining width
011
2232
4354
6575
8697
0.0E+00
1.0E+05
2.0E+05
3.0E+05
4.0E+05
5.0E+05
6.0E+05
Co
nta
ct P
ress
ure
(P
a)
Angular Position (o)
Abutment side
Lining width
Actuation side
Static
Dynamic
CONTACT PRESSURE DISTRIBUTION FORCONTACT PRESSURE DISTRIBUTION FORLEADING SHOELEADING SHOE
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01
02
0
31
41
51
61
72
82
92
10
2
0.0E+00
1.0E+05
2.0E+05
3.0E+05
4.0E+05
5.0E+05
6.0E+05
Co
nta
ct
Pre
ssu
re (
Pa
)
Angular position (o)
Abutment side
Lining width
Actuation side
010
20
31
41
51
61
72
82
92
102
0.0E+00
1.0E+05
2.0E+05
3.0E+05
4.0E+05
5.0E+05
6.0E+05
Co
nta
ct P
ress
ure
(P
a)
Angular Position (o)
Abutment side
Actuation side
Lining width
Static
Dynamic
CONTACT PRESSURE DISTRIBUTION FORCONTACT PRESSURE DISTRIBUTION FORTRAILING SHOETRAILING SHOE
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0
10
20
30
40
50
60
70
80
90
100C
on
tact
are
a (%
)
0.20 0.25 0.30 0.35 0.40
Coefficient of Friction
Leading
Trailing
CONTACT AREA WITH DIFFERENTCONTACT AREA WITH DIFFERENTCOEFFICIENT OF FRICTIONCOEFFICIENT OF FRICTION
The higher value coefficient of friction, the lower contact area.
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0.0E+00
1.0E+05
2.0E+05
3.0E+05
4.0E+05
5.0E+05
6.0E+05
0 20 40 60 80 100
Angular position (O)
Co
nta
ct P
ress
ure
(P
a)
0.20
0.25
0.30
0.35
0.40
Actuation side Abutment side
μ
CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT COEFFICIENT OF FRICTIONCOEFFICIENT OF FRICTION
(LEADING)(LEADING)
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0.0E+00
1.0E+05
2.0E+05
3.0E+05
4.0E+05
5.0E+05
6.0E+05
0 20 40 60 80 100
Angular position (O)
Co
nta
ct P
ress
ure
(P
a)
0.20
0.25
0.30
0.35
0.40
Actuation side
Abutment side
μ
CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT COEFFICIENT OF FRICTIONCOEFFICIENT OF FRICTION
(TRAILING)(TRAILING)
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50
55
60
65
70
75
80
85
90
95
100
Co
nta
ct
are
a (
%)
2.0 2.5 3.0 3.5 4.0
Actuation Pressure (Mpa)
Leading
Trailing
Contact area unchained for both shoes when different
actuation pressure are applied.
85.7% for leading and 64.2% for trailing
CONTACT AREA WITH DIFFERENTCONTACT AREA WITH DIFFERENTACTUATION PRESSUREACTUATION PRESSURE
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0.0E+00
1.0E+05
2.0E+05
3.0E+05
4.0E+05
5.0E+05
6.0E+05
7.0E+05
8.0E+05
9.0E+05
0 20 40 60 80 100
Angular position (o)
Pre
ssu
re D
istr
ibu
tio
n (
Pa)
2 MPa
2.5MPa
3 MPa
3.5 MPa
4 MPa
Actuation side Abutment side
CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT ACTUATION PRESSUREACTUATION PRESSURE
(LEADING)(LEADING)
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0.0E+00
1.0E+05
2.0E+05
3.0E+05
4.0E+05
5.0E+05
6.0E+05
7.0E+05
8.0E+05
9.0E+05
0 20 40 60 80 100
Angular position (o)
Pre
ss
ure
Dis
trib
uti
on
(P
a) 2 MPa
2.5MPa
3 MPa
3.5 MPa
4 MPa
Actuation side Abutment side
CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT ACTUATION PRESSUREACTUATION PRESSURE
(TRAILING)(TRAILING)
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50
55
60
65
70
75
80
85
90
95
100
Co
nta
ct
are
a (%
)
-15
%
-10
%
-5%
base
line
5% 10%
15%
Variation (%)
Leading
Trailing
The actual Elastic properties for lining is 3.10GPa
CONTACT AREA WITH DIFFERENTCONTACT AREA WITH DIFFERENTMATERIAL PROPERTIESMATERIAL PROPERTIES
(LINING)(LINING)
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0.0E+00
1.0E+05
2.0E+05
3.0E+05
4.0E+05
5.0E+05
6.0E+05
0 8 16 24 32 40 48 57 65 73 81 89 97 105
Angular position (o)
Co
nta
ct P
rees
sure
(P
a)
-15%
-10%
-5%
baseline
5%
10%
15%
Actuation side Abutment side
CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT MATERIAL PROPERTIESMATERIAL PROPERTIES
(LEADING)(LEADING)
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0.0E+00
1.0E+05
2.0E+05
3.0E+05
4.0E+05
5.0E+05
6.0E+05
0 8 16 24 32 40 48 57 65 73 81 89 97 105
Angular position (o)
Co
nta
ct P
rees
sure
(P
a)
-15%
-10%
-5%
baseline
5%
10%
15%
Actuation side Abutment side
CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT MATERIAL PROPERTIESMATERIAL PROPERTIES
(TRAILING)(TRAILING)
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50
55
60
65
70
75
80
85
90
95
100
Co
nta
ct a
rea
(%)
-15%
-10% -5
%
base
line
5% 10%
15%
Variation (%)
Leading
Trailing
CONTACT AREA WITH DIFFERENTCONTACT AREA WITH DIFFERENTMATERIAL PROPERTIESMATERIAL PROPERTIES(BRAKE SHOE BODY)(BRAKE SHOE BODY)
The actual Elastic properties for brake shoe body is 250GPa
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0.0E+00
1.0E+05
2.0E+05
3.0E+05
4.0E+05
5.0E+05
6.0E+05
0 10 20 31 41 51 61 72 82 92
Angular position (o)
Co
nta
ct P
rees
sure
(P
a)
-15%
-10%
-5%
baseline
5%
10%
15%
Actuation side Abutment side
CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT MATERIAL PROPERTIESMATERIAL PROPERTIES
(LEADING)(LEADING)
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Contact Pressure distribution with different modulus of elasticity(Leading shoe body)
0.0E+00
1.0E+05
2.0E+05
3.0E+05
4.0E+05
5.0E+05
6.0E+05
0 10 20 31 41 51 61 72 82 92 102
Angular position (o)
Co
nta
ct P
rees
sure
(P
a)
-15%
-10%
-5%
baseline
5%
10%
15%
Actuation side Abutment side
CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT MATERIAL PROPERTIESMATERIAL PROPERTIES
(TRAILING)(TRAILING)
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50
55
60
65
70
75
80
85
90
95
100
Co
nta
ct a
rea
(%)
0 m
m
0.5
mm
1.0
mm
1.5
mm
2.0.
mm
Installation gap
Leading
Trailing
CONTACT AREA WITH DIFFERENTCONTACT AREA WITH DIFFERENTINSTALLATION GAPINSTALLATION GAP
Highest area for leading shoe at 2mm gap (85.8%)
Highest area for trailing at 0.5mm gap (65.0%)
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0.0E+00
1.0E+05
2.0E+05
3.0E+05
4.0E+05
5.0E+05
6.0E+05
0 20 40 60 80 100
Angular position (o)
Co
nta
ct
Pre
ssu
re (
Pa
)
0.5 mm
1.0 mm
1.5 mm
2.0 mm
0 mm
Actuation side Abutment side
CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT INSTALLATION GAPINSTALLATION GAP
(LEADING)(LEADING)
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0.0E+00
1.0E+05
2.0E+05
3.0E+05
4.0E+05
5.0E+05
6.0E+05
0 20 40 60 80 100
Angular position (o)
Co
nta
ct P
ress
ure
(P
a)
0.5 mm
1.0 mm
1.5 mm
2.0 mm
0 mm
Actuation side Abutment side
CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT INSTALLATION GAPINSTALLATION GAP
(TRAILING)(TRAILING)
content
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PARAMETER CONTACT
AREA
CONTACT
PRESSURE DISTRIBUTION
COEFFICIENT OF FRICTION VARY VARY
ACTUATION PRESSURE NO VARY
E LINING VARY VARY
E BRAKE SHOE BODY VARY VARY
INSTALLATION GAP VARY VARY
content
Overall ResultsOverall Results
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STRUCTURAL MODIFICATION
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 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
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Model 2 Model 1
Model 3 Model 4 Model 5
Current Model
STRUCTURAL MODIFICATION(CTD)
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0
10
20
30
40
50
60
70
80
90
100
Co
nta
ct
are
a (
%)
Curr
en
t
Mo
de
l 1
Mo
de
l 2
Mo
de
l 3
Mo
de
l 4
Mo
de
l 5
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%
CONTACT AREACONTACT AREA
Figure :Contact area for different models
Comparison base on current model
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010
2131
41
51
62
72
82
93
0.0E+00
1.0E+05
2.0E+05
3.0E+05
4.0E+05
5.0E+05
6.0E+05
Co
nta
ct P
ress
ure
(P
a)
Angular Position (o)
Actuation side
Abutment side
Lining width
010
2131
41
51
62
72
82
93
0.0E+00
1.0E+05
2.0E+05
3.0E+05
4.0E+05
5.0E+05
6.0E+05
Co
nta
ct P
ress
ure
(P
a)Angular Position (o) Lining width
Abutment side
Actuation side
Trailing
Leading
MODEL 1MODEL 1
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010
2131
4152
6272
8393
0.0E+00
1.0E+05
2.0E+05
3.0E+05
4.0E+05
5.0E+05
6.0E+05
Co
nta
ct P
ress
ure
(P
a)
Angular Position (o)
Lining width
Abutment side
Actuation side
010
21
31
41
52
62
72
83
93
0.0E+00
1.0E+05
2.0E+05
3.0E+05
4.0E+05
5.0E+05
6.0E+05
Co
nta
ct P
ress
ure
(P
a)Angular Position (o)
Lining width
Abutment side
Actuation side
Trailing
Leading
MODEL 2MODEL 2
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0
10
21
31
42
52
63
73
84
94
0.0E+00
1.0E+05
2.0E+05
3.0E+05
4.0E+05
5.0E+05
6.0E+05
Co
nta
ct
Pre
ss
ure
(P
a)
Angular Position (o)
Leading shoe 5-1
Actuation side
Abutment side
Lining width
010
21
31
42
52
63
73
84
94
0.0E+00
1.0E+05
2.0E+05
3.0E+05
4.0E+05
5.0E+05
6.0E+05
Co
nta
ct P
ress
ure
(P
a)Angular Position (o)
Actuation side
Abutment side
Lining width
Trailing
Leading
MODEL 3MODEL 3
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010
20
31
41
51
61
71
82
92
102
0.0E+001.0E+052.0E+053.0E+054.0E+055.0E+056.0E+057.0E+05
8.0E+05
9.0E+05
1.0E+06
Co
nta
ct P
ress
ure
(P
a)
Angular Position (o)
Actuation side
Abutment side
Lining width
010
20
31
41
51
61
71
82
92
102
0.0E+001.0E+052.0E+053.0E+054.0E+055.0E+056.0E+057.0E+05
8.0E+05
9.0E+05
1.0E+06
Co
nta
ct P
ress
ure
(P
a)
Angular Position (o)
Actuation side
Abutment side
Lining width
Trailing
Leading
MODEL 4MODEL 4
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0 816 24 31 39
4755
63
71
79
86
94
102
0.0E+00
1.0E+05
2.0E+05
3.0E+05
4.0E+05
5.0E+05
6.0E+05
Co
nta
ct P
ress
ure
(P
a)
Angular Position (o)
Actuation side
Abutment side
Lining width
0 81
62
43
13
94
75
56
3
71
79
86
94
10
2
0.0E+00
1.0E+05
2.0E+05
3.0E+05
4.0E+05
5.0E+05
6.0E+05
Co
nta
ct
Pre
ss
ure
(P
a)
Angular Position (o)
Actuation side
Abutment side
Lining width
Trailing
Leadingcontent
MODEL 5MODEL 5
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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.
CONCLUSIONCONCLUSION
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THANK YOU