Asperity-Coupled Flash Heating, Stress Oscillation, and Synergistic Plastic Dissipation in Dual-Roughness Disc-Pad Brake Interfaces

Pengfei Cui; Liangbi Wang

doi:10.62051/ijmee.v8n5.02

Authors

Pengfei Cui School of Mechatronic Engineering, Lanzhou Jiaotong University, Lanzhou Gansu, 730070, China; Key Laboratory of Railway Vehicle Thermal Engineering, Ministry of Education, Lanzhou Gansu, 730070, China
Liangbi Wang School of Mechatronic Engineering, Lanzhou Jiaotong University, Lanzhou Gansu, 730070, China; Key Laboratory of Railway Vehicle Thermal Engineering, Ministry of Education, Lanzhou Gansu, 730070, China

DOI:

https://doi.org/10.62051/ijmee.v8n5.02

Keywords:

High-speed Train Disc Brake, Dual-roughness Interface, Thermo-mechanical Coupling, Elastoplastic Energy Dissipation, Thermal Instability

Abstract

To investigate the local flash temperature, stress oscillations, and elastoplastic energy dissipation induced by asperity interactions on both sides of a high-speed train disc brake, a three-dimensional transient thermo-mechanically coupled finite element model of a dual-roughness disc-pad interface was established. A fixed Weierstrass-Mandelbrot fractal morphology was used to evaluate temperature, von Mises stress, thermal penetration depth, thermoelastic power, plastic dissipation, and frequency-domain responses. The peak temperatures of the brake disc and brake pad reached 1409.5 °C and 1571.9 °C, respectively, and the corresponding peak von Mises stresses were 1079.4 MPa and 1024.6 MPa. The dominant stress frequency was 3395.6 Hz, with a relative oscillation amplitude of 312.10%. Plastic power accounted for approximately 32% and 37% of the theoretical input power in the disc and pad, respectively. Misaligned asperity contact and repeated jumps in contact stiffness jointly caused near-surface heat accumulation, high-frequency instability, and synergistic plastic dissipation.

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