Analysis of Thermomechanical Cracks of Disc Brake Used in Heavy Trucks

Abstract

In the present work, the study of fatigue failure of the disc brake of Volvo truck under thermomechanical effects across the disc thickness is reported. Both analytical and numerical approaches have been used. In the analytical approach, flat rigid asymmetric punch contact behavior was assumed at surface interaction, while in the numerical approach, the 3D finite element model of the vented disc type is subjected to thermomechanical cycles using ABAQUS software. Linear elastic material models were used to simulate the material's behavior under the applied pad pressure on the disc. Surface-to-surface type of contact was used for bodies that have arbitrary shapes with relatively large contact areas at disc pad interfaces. The crack initiated due to hydraulic pressure of 1.47 MPa on the disc was analyzed under mixed-mode (mode I and II) conditions. This analysis has shown that the crack propagated up to critical length of 6.02 mm and finally, failure of the disc brake was observed.