Coupled wear-thermal-structural multiphysics field analysis of friction linings in disk brakes

In this paper, the Archard wear model is combined with Abaqus finite element software for simulating the frictional wear of brake pads. The algorithm is verified to have good accuracy and reliability by pin-disk friction wear experiments. Then, a coupled wear-thermal-structural multi-physical field analysis of automotive single- and three-piston brake pads was carried out by using this method in order to explore their wear and braking characteristics in depth. The results show: in the wear-thermal coupling simulation, the contact pressure distribution of the three pistons is more uniform than that of the single piston, and the maximum stress is reduced by about 47.8% (from 4.113 to 2.145 MPa) compared to the single piston; the rate of temperature rise for the triple piston was faster than the single piston, ending at a temperature of about 103°C, which was 12°C higher than the single piston. In terms of wear mass, the triple piston is more than the single piston (about 19.21 mg), but the triple piston is more homogeneous in terms of surface wear morphology. In addition, in the pin-disk experiments, the average coefficient of friction increases and then decreases with the increase in rotational speed; The average coefficient of friction increases and then decreases slightly as the pressure increases; The effect of rotational speed on the wear mass is small, but the wear mass increases with increasing pressure.