Train Brake Pad Wear Analysis Using Finite Element Method

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Wear is the damaging, gradual removal or deformation of material of contacting solid surfaces in relative motion with each other. During braking, wear occurs at the brake disc-pad contact and is predominant at the brake pad more than the brake disc. If it is not accurately predicted and necessary action taken, the repercussions of the failure of this component can be catastrophic. So, this raises an urge to conduct a study that will help in predicting the wear of the brake pad and plausible maintenance times scheduled.In this thesis, we simulate braking at 22 stations of the AALRT East-West Line from Ayat 2 to Tor Hailoch using FEM to ascertain the train brake pad temperature build up from repeated braking, its effect on contact pressure distribution and wear, ANSYS 2019 R1 is used for this wear simulation. The temperature is obtained from a transient thermal analysis and a thermal structural analysis is adopted to attain the contact pressure whereas the wear depth is evaluated by the Archard’s linear wear law absorbed in ANSYS. Generally, the temperature of the brake pad increases after every braking and reduces during the train movement from station to station but does not go back to the initial ambient temperature. The contact pressure increases with increase in temperature, Wear depth is evaluated from contact pressure and temperature distribution, which is obtained from finite element simulation results and is an input into the Archard’s wear equation. It is observed that increase in temperature leads to increase in contact pressure which in turn leads to an increase in wear. A maximum Temperature of 385.56℃ was reached and a cumulative wear of 19.085���� was recorded.Therefore, the ability to predict train brake pad wear using Finite Element Analysis will help maintenance personnel to establish the appropriate time for inspection and replacement as well as mitigation of wear.

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Train Brake Pad Wear Analysis Using Finite Element Method

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