Design synthesis of non-symmetrically loaded high-performance disc brakes: Part 3: Verification and optimization

Abstract

Two successful wheel-hub-mounted disc designs and main problems related to this type of disc are presented in Part 1 of the paper. Following material properties measurements, different types of finite element (FE) analyses were performed in Part 2 and thermoelastic instability and disc plasticity modelled for the TGV powercar disc. The results showed that different FE analyses give very similar disc deflection during braking. Following previous work, in this paper (Part 3), full verification of disc temperatures, permanent deflections and stresses have been conducted. Very good correlation of FE results with dynamometer and vehicle service data was achieved. By proving the validity of the proposed modelling procedures, an optimization methodology was developed and applied, leading to the development of a new disc design. The comparison with the existing disc showed the advantages and limitations of both designs. The recommendations for a successful wheel-hub-mounted disc design are also given. The analytical and experimental work confirmed the efficiency and robustness of the developed methodology, making it suitable for industrial use, by offering substantial savings and reducing development risks.