全封闭湿式多盘制动器的数值模拟分析
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摘要
全封闭湿式多盘制动器摩擦盘温度场和应力场的计算是设计制动器和选择摩擦副材料的重要理论依据。本文在参阅国内外相关文献的基础上，对全封闭湿式多盘制动器摩擦副接触表面的压力场和摩擦盘的瞬态温度场及应力场进行了研究。
介绍了制动器热传导基本方程、制动器结构非线性分析算法及制动器磨擦副接触非线性算法，并对解决全封闭湿式多盘制动器的热传导问题、制动器结构非线性问题及摩擦副接触问题的方法进行了详细的讨论。
依据全封闭湿式多盘制动器摩擦盘的实际几何尺寸，建立了二维轴对称有限元分析模型，对模型进行了必要的简化和假设，确定了全封闭湿式多盘制动器有限元分析模型的边界条件，并充分考虑了摩擦盘间温度场和应力场耦合问题。在此基础上采用ANSYS有限元分析软件，对紧急制动工况和持续制动工况的摩擦副接触表面压力、摩擦盘温度场和应力场进行了模拟计算。较真实地模拟了制动器的制动过程，探讨了不同制动工况下摩擦盘偶件温度场和应力场的分布规律。
论文还从能量的角度为制动器设计了冷却系统，并对冷却后的制动器摩擦盘进行了温度场和应力场的有限元计算，检验了该冷却系统设计的合理性。
Calculating the thermal and stress of the wet multi-disc brake is one of the maincontent in the brake designing and material selecting. Based on extensive references tothe research work and literature in this field, the research of contact condition betweentwo friction discs and the distribution rules of transient thermal field and thermal stressof traction parts were carried out.
Starting from the heat conduction differential equation of instant thermal field, thispaper introduces functional thermal transmittance, construction non-linearity and contactnon-linearity of the wet multi-disc brake, explores in detail about how to solve them
The finite element model of the wet multi-disc brake was realistically constructedusing two-dimensional axisymmetric element. By necessary assumption and simplify thispaper confirmed the boundary condition of FEM model. Also the coupling of transientthermal and stress was explored sufficiently. In this paper finite element software ofANSYS was used in the analysis of contact press between two friction discs and thermalfield and stress field of friction disc during emergency braking and lasting process. Basedon the calculation results, the distribution rules of thermal field and thermal stress oftraction parts were studied. The results simulate the braking process objectively.
Based on the braking energy theory this paper designs appropriate cooling systemfor the wet multi-disc brake. By FEM analysis of thermal field and stress field to verifythe rationality of the cooling system.
介绍了制动器热传导基本方程、制动器结构非线性分析算法及制动器磨擦副接触非线性算法，并对解决全封闭湿式多盘制动器的热传导问题、制动器结构非线性问题及摩擦副接触问题的方法进行了详细的讨论。
依据全封闭湿式多盘制动器摩擦盘的实际几何尺寸，建立了二维轴对称有限元分析模型，对模型进行了必要的简化和假设，确定了全封闭湿式多盘制动器有限元分析模型的边界条件，并充分考虑了摩擦盘间温度场和应力场耦合问题。在此基础上采用ANSYS有限元分析软件，对紧急制动工况和持续制动工况的摩擦副接触表面压力、摩擦盘温度场和应力场进行了模拟计算。较真实地模拟了制动器的制动过程，探讨了不同制动工况下摩擦盘偶件温度场和应力场的分布规律。
论文还从能量的角度为制动器设计了冷却系统，并对冷却后的制动器摩擦盘进行了温度场和应力场的有限元计算，检验了该冷却系统设计的合理性。
Calculating the thermal and stress of the wet multi-disc brake is one of the maincontent in the brake designing and material selecting. Based on extensive references tothe research work and literature in this field, the research of contact condition betweentwo friction discs and the distribution rules of transient thermal field and thermal stressof traction parts were carried out.
Starting from the heat conduction differential equation of instant thermal field, thispaper introduces functional thermal transmittance, construction non-linearity and contactnon-linearity of the wet multi-disc brake, explores in detail about how to solve them
The finite element model of the wet multi-disc brake was realistically constructedusing two-dimensional axisymmetric element. By necessary assumption and simplify thispaper confirmed the boundary condition of FEM model. Also the coupling of transientthermal and stress was explored sufficiently. In this paper finite element software ofANSYS was used in the analysis of contact press between two friction discs and thermalfield and stress field of friction disc during emergency braking and lasting process. Basedon the calculation results, the distribution rules of thermal field and thermal stress oftraction parts were studied. The results simulate the braking process objectively.
Based on the braking energy theory this paper designs appropriate cooling systemfor the wet multi-disc brake. By FEM analysis of thermal field and stress field to verifythe rationality of the cooling system.
引文
1 王晶．车用湿式多盘制动器．建筑机械，2000(2)：35-37
2 韩风麟．湿式摩擦材料发展与现状．世界机械工业，1986(5)
3 翁振福．湿式烧结金属摩擦片缩比模拟实验．工程机械，1993(4)：15-17
4 张德林．湿式多片离合器台架试验条件模拟计算确定方法探讨．摩擦材料，1982(2)
5 孙冬野，张云龙，诸文农等．湿式多片制动器油槽内三维抛物流的数值计算．农业工程学报，1995，11(4)：79-84
6 蔡中青，黄宗益．湿式全盘式制动器设计计算．工程机械，1999，30(10)：22-25
7 战仁军．BP网络在基于知识的摩擦学设计中的应用．机械科学与技术，1997，16(4)：719-723
8 黄洪钟，李海滨．有限元的神经网络计算方法研究．机械强度，2003，25(3)：298-301
9 范绪箕．关于热弹性力学的耦合理论．力学发展，1982(12)：339-345
10 Thomas J.Mackin,Steven C.Noe. Thermal cracking in disc brakes. Engineering Failure Analysis 2002 9,63-76
11 曹玉璋．实验传热学．北京：国防工业出版社，1998
12 田福祥．盘式制动器的摩擦片压力和制动力矩．工程机械，1998，29(10)：15-17
13 Takayuki Matsurnoto. The influence of paper-base friction material porosity on the performance of a wet clutch SAE Paper NO:941032,1994
14 Takayuki Matsumoto. A study of the influence of porosity and resiliency of a paper-Based friction material on the friction characteristics and heat resistance of Material. SAE Paper NO: 932924, 1993
15 Katsuhiro Ito, Keith A.Barker. Designing paper type wet friction material for high strength and durability, SAE Paper, NO:982034,1998
16 P.Zagrodzki,S.A.Truncone. Generation of hot spots in a wet multitask clutch during short-term engagement. Wear.2003, 254:474-491
17 温诗涛．摩擦学原理．北京：清华大学出版社，1991
18 何君毅，林祥都．工程结构非线性问题的数值解法．北京：国防工业出版社，1994
19 J.R.Barber,M.Ciavarelia. Contact mechanics. International Journal of Solids and Structures, 2000 37:29-43
20 陈火．Marc有限元实例分析教程．北京：机械工业出版社，2002．
21 Przemyslaw Zagrodzki. Analysis of temperatures and stresses in wet friction disks involving thermally induced changes of contact pressure. SAE Paper NO:982025,1998
22 Francis E.Kennedy,Dan Frusescu,Jiaying Li.Thin film thermocouple arrays for sliding surface temperature measurement.Wear. 1997,207:46-54
23 王国强．实用工程数值模拟技术及其在ANSYS上的实践．西安：西北工业大学出版社，1999
24 杨世铭，陶文铨．传热学．北京：高等教育出版社，1998
25 王勖成，邵敏．有限单元法基本原理和数值方法．北京：清华大学出版社，1997
26 王勖成．有限单法．北京：清华大学出版社，2003．7
27 J.T.Stadter, R.O.Weiss. Analysis of contact through finite gaps. Comput Struct, 1979,10:67-73
28 W.R.L.Underhili,M.A.Dokainis,etc. A Method for contact problems using virtual elements.Comut Meth Appl Mech Engng, 1997,143:229-247
29 G..Zavarise,P.Wriggers and A Schrefler. A method for solving contact problems. Int J.Numer Meth Engng, 1998,42:473-498
30 王水林，邓建辉，葛修润．改进的拉氏乘子法在接触磨擦问题中的应用．岩土工程学报，1998，20(5)：64-67．
31 J.C.Simo,P.Wrigger and R.L.Tayor. A perturbed Lagrangian formulation for the finite element solution of contact problems. Comput Meth Appl Mech Engng, 1995,50:163-180
32 P.Wriggers,O.Scherf. Adaptive finite element techniques for frictional contact problems involving large elastic strain. Comput Meth Appl Mech Engng, 1998,151:593-603
33 M.H.Refaat, S.A.Mequid. A new strategy for the solution of frictional contact problems. Int J.Numer Meth Engng, 1998,43:1053-1068
34 战凯．10t井下自卸车的研制．矿冶，1996(5)：1-7
35 ANSYS公司北京办事处．ANSYS热分析指南，1998
36 王国强．实用工程数值模拟技术及其在ANSYS上的实践．西安：西北工业大学出版社，1999
37 诸文农．底盘设计．北京：机械工业出版社，1981
38 L．鲁道夫编，张蔚林，陈名智译．汽车制动系统的分析与设计．北京：机械工业出版社，1985
39 阎清东，宿新东．湿式多片制动器摩擦衬片初始压力分布研究．北京理工大学学报，2000(20)：42-46
40 M.Tirovic,A.J.Day. Disc brake interface pressure distribution. Proc Instn Mech Engrs. 1991,205:137-146
41 A.Molinari,Y.Estrin,S.Mercier. Dependence of the coefficient of Friction on the sliding conditions in the high velocity range. ASME Journal of Tribology, 1999,121:35-41
42 杨世铭，陶文铨．传热学．北京：高等教育出版社，1998
43 K.Friedrich,Z.Neder. Numerical and finite element contact temperature analysis of real composite steel surfaces in sliding contact. Tribology International, 1998,31:669-686
44 F.E.Kennedy Jr. Surface temperatures in sliding systems-A finite element analysis.ASME Journal of Tribology, 1991,103:90-96
45 张文春．汽车理论．北京：机械工业出版社，1995
46 余志生．汽车设计．北京：机械工业出版社，2000
47 高梦熊．封闭多盘湿式制动器冷却系统的设计．工程机械，1999，30(2)：21-22
48 徐灏．机械设计手册．北京：机械工业出版社，1991
2 韩风麟．湿式摩擦材料发展与现状．世界机械工业，1986(5)
3 翁振福．湿式烧结金属摩擦片缩比模拟实验．工程机械，1993(4)：15-17
4 张德林．湿式多片离合器台架试验条件模拟计算确定方法探讨．摩擦材料，1982(2)
5 孙冬野，张云龙，诸文农等．湿式多片制动器油槽内三维抛物流的数值计算．农业工程学报，1995，11(4)：79-84
6 蔡中青，黄宗益．湿式全盘式制动器设计计算．工程机械，1999，30(10)：22-25
7 战仁军．BP网络在基于知识的摩擦学设计中的应用．机械科学与技术，1997，16(4)：719-723
8 黄洪钟，李海滨．有限元的神经网络计算方法研究．机械强度，2003，25(3)：298-301
9 范绪箕．关于热弹性力学的耦合理论．力学发展，1982(12)：339-345
10 Thomas J.Mackin,Steven C.Noe. Thermal cracking in disc brakes. Engineering Failure Analysis 2002 9,63-76
11 曹玉璋．实验传热学．北京：国防工业出版社，1998
12 田福祥．盘式制动器的摩擦片压力和制动力矩．工程机械，1998，29(10)：15-17
13 Takayuki Matsurnoto. The influence of paper-base friction material porosity on the performance of a wet clutch SAE Paper NO:941032,1994
14 Takayuki Matsumoto. A study of the influence of porosity and resiliency of a paper-Based friction material on the friction characteristics and heat resistance of Material. SAE Paper NO: 932924, 1993
15 Katsuhiro Ito, Keith A.Barker. Designing paper type wet friction material for high strength and durability, SAE Paper, NO:982034,1998
16 P.Zagrodzki,S.A.Truncone. Generation of hot spots in a wet multitask clutch during short-term engagement. Wear.2003, 254:474-491
17 温诗涛．摩擦学原理．北京：清华大学出版社，1991
18 何君毅，林祥都．工程结构非线性问题的数值解法．北京：国防工业出版社，1994
19 J.R.Barber,M.Ciavarelia. Contact mechanics. International Journal of Solids and Structures, 2000 37:29-43
20 陈火．Marc有限元实例分析教程．北京：机械工业出版社，2002．
21 Przemyslaw Zagrodzki. Analysis of temperatures and stresses in wet friction disks involving thermally induced changes of contact pressure. SAE Paper NO:982025,1998
22 Francis E.Kennedy,Dan Frusescu,Jiaying Li.Thin film thermocouple arrays for sliding surface temperature measurement.Wear. 1997,207:46-54
23 王国强．实用工程数值模拟技术及其在ANSYS上的实践．西安：西北工业大学出版社，1999
24 杨世铭，陶文铨．传热学．北京：高等教育出版社，1998
25 王勖成，邵敏．有限单元法基本原理和数值方法．北京：清华大学出版社，1997
26 王勖成．有限单法．北京：清华大学出版社，2003．7
27 J.T.Stadter, R.O.Weiss. Analysis of contact through finite gaps. Comput Struct, 1979,10:67-73
28 W.R.L.Underhili,M.A.Dokainis,etc. A Method for contact problems using virtual elements.Comut Meth Appl Mech Engng, 1997,143:229-247
29 G..Zavarise,P.Wriggers and A Schrefler. A method for solving contact problems. Int J.Numer Meth Engng, 1998,42:473-498
30 王水林，邓建辉，葛修润．改进的拉氏乘子法在接触磨擦问题中的应用．岩土工程学报，1998，20(5)：64-67．
31 J.C.Simo,P.Wrigger and R.L.Tayor. A perturbed Lagrangian formulation for the finite element solution of contact problems. Comput Meth Appl Mech Engng, 1995,50:163-180
32 P.Wriggers,O.Scherf. Adaptive finite element techniques for frictional contact problems involving large elastic strain. Comput Meth Appl Mech Engng, 1998,151:593-603
33 M.H.Refaat, S.A.Mequid. A new strategy for the solution of frictional contact problems. Int J.Numer Meth Engng, 1998,43:1053-1068
34 战凯．10t井下自卸车的研制．矿冶，1996(5)：1-7
35 ANSYS公司北京办事处．ANSYS热分析指南，1998
36 王国强．实用工程数值模拟技术及其在ANSYS上的实践．西安：西北工业大学出版社，1999
37 诸文农．底盘设计．北京：机械工业出版社，1981
38 L．鲁道夫编，张蔚林，陈名智译．汽车制动系统的分析与设计．北京：机械工业出版社，1985
39 阎清东，宿新东．湿式多片制动器摩擦衬片初始压力分布研究．北京理工大学学报，2000(20)：42-46
40 M.Tirovic,A.J.Day. Disc brake interface pressure distribution. Proc Instn Mech Engrs. 1991,205:137-146
41 A.Molinari,Y.Estrin,S.Mercier. Dependence of the coefficient of Friction on the sliding conditions in the high velocity range. ASME Journal of Tribology, 1999,121:35-41
42 杨世铭，陶文铨．传热学．北京：高等教育出版社，1998
43 K.Friedrich,Z.Neder. Numerical and finite element contact temperature analysis of real composite steel surfaces in sliding contact. Tribology International, 1998,31:669-686
44 F.E.Kennedy Jr. Surface temperatures in sliding systems-A finite element analysis.ASME Journal of Tribology, 1991,103:90-96
45 张文春．汽车理论．北京：机械工业出版社，1995
46 余志生．汽车设计．北京：机械工业出版社，2000
47 高梦熊．封闭多盘湿式制动器冷却系统的设计．工程机械，1999，30(2)：21-22
48 徐灏．机械设计手册．北京：机械工业出版社，1991