brake

Proceedingsofthe2009IEEE

InternationalConferenceonMechatronicsandAutomation

August9-12,Changchun,China

ParametricFiniteElementModellingandNonlinear

Analysis

ofVehicleBrake

JiuchenFan},2,ZhaojunYangI

,JixinWangt,ShuweiDingI,ChangliangLiulandZongchengShil

ICollegeofMechanicalScienceandEngineering,JilinUniversity,Changchun,JilinProvince,China

2College

ofMechanicalEngineering,BeihuaUniversity,Jilin,JilinProvince,China

fanjiuchen1973@,yzj@,jxwang@

1762

Abstract-Aparametricplatformforthedrumbrake

automaticmodellingandnonlinearanalysisistablished

withthe

parametricprogramminglanguage(APDL)and

urinterfacedesignlanguage(UIDL)

platformiasytouandflexible,requiringuronlyto

inputdifferentparametersinthedialogboxes,then

geometricmodelcanbecreatedautomaticallybyassigning

valuestoparameters,andthenmeshing,solvingand

outputtingofresultscanbeimplementedeasilybythis

adrumbrakeofaheavyvehicleasa

typicalexample,acontactanalysisoftheemergency

ulationresults

correspondtotherealities,thusconfirmingthevalidityof

this

platformforparametricmodellingandnonlinear

analysis,whichcanprovideaconvincingbasisfor

shortening

brakedevelopmentcycle,forstructural

optimizationandforrealizingthecompletelydigitaldesign

ofthedrumbrake.

IndexTerms-VehicleEngineering,drumbrake,APDL,

UIDL,contactanalysis,ParametricFiniteElementModelling.

UCTION

Drumbrakeiswidelyudinpasngercarsandtrucks,

andthecurityofpersonsandvehiclesisdirectlylinkedto

ofdrumbrakeinvolvesthecomplex

mechanicalandthermalloadcomputation,andtheu

of

numericalsimulationtechnologyonbrakeperformance

,finiteelement

technologyinthestudyofbrakeperformancehasbeenud

increasinglyandwidely[1-2],andgraduallythecommon

functionsoffiniteelementtechnologycombinedwiththo

specialfunctionswereudinvariousfields[3-6].Drum

ore,finite

elementanalysissoftwarecanbeudtoperformthedrum

brakethree-dimensionalparametricmodellingandanalysis.

Theparametricplatformdesigning

ofbrakesystematprent

focusmainlyon3Dgeometryandtheoreticalcalculation

ofa

simplefiniteelementmodel,what'smore,itdoesnotcontain

ore,aparametricplatformforthe

drumbrakewhichcanaccomplishautomaticallymodelling

andnonlinearanalysisistablishedwithcondary

developmentfunction

arametricdesign

languageincludesparametricprogramminglanguage(APDL)

andurinterfacedesignlanguage(UIDL).APDLcan

completethecirculatoryanalysisfunctionwhenthereare

978-1-4244-2693-5/09/$25.00©2009IEEE

changesonlyingeometricmodelsorloadswithoutchangesin

analysisprocess[7].UIDListhespecialdesignedlanguage

forcompilingandaddingANSYSgraphicalinterface,andit

canorganizefavourablemenusystemandfeature-richdialog

andUIDL,theplatformforparametric

modellingandanalysis

ofdrumbrakeisdeveloped,andthe

mainmenusystemisconstructed,andthedialogboxesfor

inputtingparametersandpickingentitiesareestablished.

Parametricurprogramsarecompiledtoachievethe

automationofmodelling,analyzingandcalculatingofthe

rakeudinacertainheavyvehicleis

takenasanexampletoillustratetheprocessof

parameterization,andthenacontactanalysisunderthe

emergencybrakingcaiscarriedout.

INITEELEMENTMODELLINGAND

ANALYSISPARAMETERIZING

gflowofparametricplatform:

Drumbrakeiscompodofbrakedrum,brakeshoe,

frictionplate,actuatingdevice,

differencesinstructuralformaremainlyembodiedin

actuatingdevice,aswellasthesupportformofthebrake

udtocompiledatafiles

ofvariousparts,and

formindependentfiniteelementanalysismoduleofvaries

udtomakefriendlyman-machine

interface,bywhichurscanlectanalysismoduleunderthe

guidance,andentertheparametersofstructure,materials,

meshcontrolling,

functionsofautomaticsolvingandresultsoutputtingcanbe

enabledtofinishthefiniteelementanalysisprocessofthe

workingflowof

parametricplatform.

terizingprocesswithAPDL:

Fig.2istheparameterizingprocess

ofleadingandtrailing

shoebrakewhichcontainsbrakedrum,brakeshoeand

frictionplate,andworkingflow

APDL,wecanachieveparametricsolidmodelling,parametric

meshinggeneration,parametricmaterialdefinition,parametric

boundaryconditions,parametricanalysisoptions,parametric

eprocess

canbecalledbythefollowingmenusanddialogboxes

producedbyUIDL.

Structurelectionandanalysistype

Thectionofbrakedrumisdividedintoveral

hod

ofmappedmeshisapplied.

First,lecttwokeypointsfrombothinternalandexternal

surfaces,andtheplatformcalculatesthethicknessofthedrum

ly,

tthedivisionnumberofwallthicknessasavariablenamed

'volu_mesh'.Thenthewallthicknessisdividedbythe

variable,andattainingthevaluewhichisudtocontroleach

y,bypickingpointsatcomer,the

method

ofmappedmeshisudtocompletethefiniteelement

msaregivenas

follows:

*GET,xi,KP,618,LOC,X,

*GET,X2,KP,634,LOC,X,

GX=3

area_mesh=(XI-X2)/G_X

LESIZE,all,area_mesh,,,,,,,1

Togeneratetheentirefiniteelementmodel

ofthebrake,two

pointsattachedtothebrakedrumrotationaxisarepickedup

berofthemesh

divisionsalongcircumferenceistasavariablenamed

'volu_mesh'.Choo'Solid45'elementtypeandlect

materialmodels,thenmakethecrossctionofbrakedrum

rotatearounditsaxis360degreestogeneratethethree-

ebrakedrumwith

goodqualitymeshesistablishedbyusingvariablesnamed

'areamesh'and'volumesh'.

--

Select'Solid45'solidelementtypeanddeterminethe

gth

oftheoverallelementsizeis

definedasavariablenamed'shoe_mesh'.Thenmeshbrake

'Solid45'solid

elementtypeandmaterialmodel,andthenmeshfrictionplate

thebrakeshoeand

efiniteelementmodelofthedrumbrake

istablished.

3)MaterialProperties:Materialpropertiesincludeelastic

modulus,poison'sratio,densityandfrictioncoefficient.

4)ParameterizationofBoundaryConditions:Boundary

conditionsinclude:

(1)Radialandaxialdisplacements

ofbrakeshoearezeroat

circumferentialrotational

displacementisrelead

(2)Radialandaxialdisplacementsofbrakedrumarezeroat

tialforceisappliedatthe

circumferentialdirection.

(3)Atthedrivensideofbrakeshoe,brakeshoereceives

actuatingforcefromactuatingdevice.

Thenodestobeconstrainedareputtogetherasnodegroups

fortheconvenience

groupsinclude:brakeshoepin-holes(N_PINIandN_PIN2),

actuatingforces(N_camiandN_cam2),andboltconnections

(N_bolt_

WandN_bolt_W).

sofdesigninginterfacewithUIDL:

UIDLachievesthefunctionofdesigninginterfaceby

dtoestablish

Brakedrum

meshcontrol

parameters

Boundary

conditionsof

displacement

Generatefiniteelementmodel(meshing)

Meshcontrolof

brakeshoesand

frictionplates

parameters

Createthree-dimensionalsolidmodel

ngflowchart

1)Parameterizationofsolidmodel:WhenusingAPDLto

makeaparametricmodel,itisnecessarytoavoiddirectly

s,it's

bettertouthelectingfunctions,suchaspositionlecting,

associationlecting,subordinationlectingandproperty

lectingtoachieveparametricmodelling[8].Thehybrid

modellingmethodisappliedtobuildthesolidmodel

ofbrake

inthispaper,whichwillbeudtocreatethefiniteelement

model.

2)ParameterizationofMeshingandControlling:Inorderto

enablethemeshgenerationtobemoreconvenientand

guaranteethemeshqualityandsimulationaccuracy,every

solidpartissub-blockedintoveralregularshapebodies.

Thesymmetriccharacteristicsofthegeometricmodelshould

beudtoreducetheduplication

ofmodelling.

Fig.2Parametricmodellingandcontactanalysisflowchart

APDLmacrofile(Analysismodules)

1763

~.aterialpropsinputIII

dtoestablishfunction

ntrol-fileismadeupofacontrol-fileheader

ldingblocksaremadeup

oftwokinds:menubuildingblocks,functionbuildingblocks.

,

andfunctionbuildingblocksareestablishedin

.

trol-file

inurworkingdirectory,andaddur-defineinformationof

menubuildingblockbetweentwobuildingblocks;locate

ur-definemenuinformationbuildingblockattheend

of

control-fileheadertomakeiteasiertoexamineandedit;

launchANSYS(theur-defineddialogboxcanbefoundin

menu);editUIDLprogramofthecorrespondingdialogbox;

rworking

directory,locateur-definedfunctionbuildingblockatthe

,thenarrange

he

designingofthemenuanddialogboxisfinished.

Thisplatformconsists

of8parts:parametersinputting,

3Dmodelcreation,finiteelementmodelcreation,contactpair

creation,applyingboundaryconditions,solutionandanalysis,

amongwhich"parametersinputting"and"solutionand

analysis"arecond-levelmenu,theothersarefunction

.3-6arefourtypicaldialogboxesofcontact

anI

FigADialogboxofstructureparametersinputting

~thedruabrakecreat

1°·21I

1°.

032I

1°·148I

1°.

048I

1°·145I

1

35I

1"°I

1°.

0175I

I~

Cancel

CancelIOK

widthoflining--------------B

shoeandliningmeshsize

------------shoe_mesh

OK

drumhoop_meshsize

------------VolU_ITIesh

------------------G_X

meshsizeparameterofthedrumbrakeinput:

drumradiaI_meshsize

Y_-P

X_coordinateofguidepulley-A

~structureparaaeterinput•

Y_coordinateofanchorpirr-t-K

fullangl.e0f1ining-----fulIA

drumbrakestructureparameterinput

brakedruminnerr-edias:-----R

X_coordinateofanchorpin-v-E

startangleoflining---StartA

00

1°·28

she,------PBXY

thedrumbrakematerial,propertiesinput:

sho12------EX

she,------DENS

Fig.5Dialogboxofmeshingcontrolling

~boundaryconditionapplyIII1ining------EX

1ining------PBXY

1ining------DENS

drum------EX

drum------PBXY

drum------DENS

17

1°3

00

1°.

27

forceandtorqueinput:

force

brakin~torque

OK

1~5688

119800

CancelI

OKCancel

Fig.6Dialogboxofboundaryconditionsapplying

Fig.3Dialogbox

ofmaterialparametersinputting

ES

Takethedrumbrakeforanexample,andnonlinear

contactanalysisofthebrakeintheemergencybrakingcais

carriedout.

ngsolidmodels:

Fig.?showsthesolidmodelofbrakeshoes,frictionplates,

elisgeneratedafterinputtingthe

parametersinthedialogboxeswhichareshowedinFigs.3-4.

ngfiniteelementmodel:

1764

issstresscontourofthebrakedrum

Fig.9Radialdisplacementcontour

ofthebrakedrum

.lSlE+09

.132E+09

.113E+09

.94SE+08

.7S7EtOS

.569E+08

.381E+08

.170E+09

.194E+08

578981

_212E-04

.27fE-03

.213E-03

.149E-03

.851E-04

-.235E-03

-.I'BE-03

-.299B-03

-

.428E-04

-.107

E-03

Fig.8showsthefiniteelementmodelwhichisgenerated

afterinputtingmeshparametersinthedialogboxshowedin

Fig.5.

isresults:

Boundaryconditionsintheemergencybrakingcaare

inputtedintothedialogboxshowedinFig.6,thenthe

deformationandstress

ofthebrakedrum,brakeshoesand

tour

oftheradial

displacementandequivalentstressofthebrakeareobtained

imumradial

displacementisO.277mm,

maximumequivalentstressis170MPa,whichisattheroot

of

theflangefilletofthedrum,

maximumstressofthebrakeshoesis255MPa,whichis

besidethesupportingpin-hole,

maximumstressoffrictionplatesis47MPa,whichisbeside

thesupportingpart

ofthebrakeshoe,andshowedinFig.12.

Theanalysisresultsofthedeformationandthepositionof

stressconcentrationcorrespondtotherealities.

Fig.?Solidmodel579829

.289E+OB

.571E+08

.854Et08

.114Et09

.142Et09

.170E+09

.199E+09

.227E+09

.25SE+09

Fig.11Vonmissstresscontourofthebrakeshoes

Fig.8Finiteclementmodel

1765

.106E+07

.624E+07

.114E+08

.166E+08

.218E+08

.270E+08

.322E+08

.374E+08

.426E+08

.477E+08

[6],,,,,.

"RearchoncrankshaftFEAsystem

ofparametric3Dintegralmodel,'

TransactionsoftheCSAE,vol.20,no.6,pp.27

-30,2004.

[7],,."SecondaryDevelopmentTechnology

ofANSYSBadonVB,"JournalofChongqingVocational&Technical

Institute,no.2,pp.144

-145,2006.

[8]nahi,,,,"Development

ofaparametricfinite

elementmodeloflowercervicalspineinsagitalplane,"IEEEEMBS

Conference'sproceeding,pp.1739-1741,August30-Sept.3,2006[EMBS

AnnualInternationalConferenceNewYorkCity,USA,Aug30-Sept3,

2006].

Fig.12Vonmissstresscontourofthefrictionplates

SION

Amethod

ofestablishingthedigitalplatformofvehicle

nddevelopingtoolsAPDLand

UIDLinANSYS,thedigitalplatformofdrumbrake

gitalplatformis

characteridbytheoptimalinterfaceandstableoperation.

Thedrumbrakefiniteelementanalysiscanbeimplemented

nearcontactanalysisforthedrumbrake

ofacertainheavyvehicleiscarriedout,andtheanalysis

resultsofnonlinearcontactcorrespondtotherealities.

Comparedwithclassicaldesigningmeansandanalysis

methods,thisdigitalplatformcanprovidehighefficient

digitaldesignandanalysiscircumstancesforthedrumbrake,

platformischaracterizedbyconsiderableflexibility,aries

ofsimilardrumbrakemodelsanddifferentconditionsofthe

samedrumbrakecanbeanalydbythisplatform.

ACKNOWLEDGMENT

TheauthorsgratefullyacknowledgedtheProjectofJilin

ProvinceTechnologyDevelopmentPlan(20080I09)and

Project

ofChangchunApplicationTechnicalRearch

Plan(3D508M912414).

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1766