Thermo-Mechanical Coupling Analysis And Design Of Aluminum Matrix Composite Brake Disc For Electric Vehicles

With the rapid development of automobile industry, environment pollution and emissions, which were caused by cars, have been paid more and more attention to. Electric vehicles, which have the advantages of low noise, high driving stability and zero emission, will be an important developing trend for the automotive industry in the future. However, the continuous driving distance of electric vehicles restricts its application. The lightweight of the electric vehicle is one of the effective method to increase the continuous driving distance, and lightweight of brake disc is one of the important method for that of the whole vehicles. Aluminum matrix composites can applied as a new material for the lightweight of brake disc because of good wear resistance hig specific strength. A wide range of applications and the rapid development of new materials gave a wide developing space for the lightweight of brake disc. Based on theoretical analysis and finite element simulation method? stress field and temperature field distribution of the brake disc during brake process are analyzed.Furthermore, the design rules of aluminum matrix composites brake discs are also discussed. The results not only have important academic value but also can guide the design rule of aluminum matrix composites brake disc.The main work of this paper is as follows:1. Based on the real dimensions of braking disc, the CAD models of braking disc were developed by using CATIA software and the finite element model are also developed by using abaqus software. The stress field and temperature field distribution of SiCp/Al composites brake disc and HT250 brake disc with same thickness are compared under emergency brake conditions at different initial speed of 60km/h and 100Km/h, 160Km/h.The results show that the dimension characters of brake disc must be designed again because of the difference of mechanical properties of different disc materials. The variation of stress field and temperature field with the thickness of the disc are discussed, and the proper thickness of SiCp/Al composites brake disc are proposed. Also the lightweight of SiCp/Al composites brake are discussed.3. Variation of the highest stress and temperature of SiCp/Al composites ventilated disc under the continuous emergency brake conditions with 10 times are analyzed. Also, the effect of design characters such as thickness, ventilated rib height, Ration of ventilated rib length to width on the stress and temperature field distribution are discussed. Based on the results, the design rules of SiCp/Al composites ventilated disc are proposed. The application prospects of the aluminum matrix composite brake discs instead of gray cast iron brake disc on the electric car are studied in this paper, and the lightweight effect is also discussed. The research results have important engineering significance and practical value for the electric vehicle lightweight.