列车盘式制动器温度场与振动模态的分析研究
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摘要
制动盘和闸片是高速列车盘式制动器的重要组成部分,本文在查阅大量相关文献的基础上,以制动盘和单个制动块组成的“基本制动元”为研究对象,应用有限元软件ABAQUS,建立了“基本制动元”模型,采用热—机耦合方法,研究了稳态制动温度场的变化规律,并进行了实验验证,提出了等面积制动块形状因子的概念,对制动盘和闸片进行了实模态分析,研究了结构和约束对制动盘和闸片固有频率的影响规律,为制动器减振降噪提供依据。
以常用的圆形制动块与制动盘构成的摩擦副为研究对象,采用定速、恒压条件进行了制动温度场和接触压力的仿真分析。结果表明,制动盘和制动块的接触面温度变化曲线都呈现出锯齿状的变化特征,制动盘温度场云图由开始的尾巴形状,逐渐过渡到环带状,最后由斑点状高温区域相互连通而形成条带状分布。制动块温度场云图由开始的舌头状逐渐变为带状,温度向出口方向扩散,最后沿厚度方向辐射至整个模型上。制动温度场实验研究表明,模拟温度曲线和实验温度曲线趋势相同。说明使用“基本制动元”模型进行研究的方法是可行的,其结果也具有揭示过程本质特征的特点。
提出了制动块等面积形状因子的概念,并进行了公式推导,即Fs=0.0174R·θ/L表达式中既包含了制动块关键要素,又包含了摩擦半径,所以能够比较全面的反映摩擦副之间的相互作用。形状因子描述的是一类图形的属性,等面积形状因子可以衡量制动块形状的区别,也可反映其在制动盘上的摆放位置不同。仿真结果对比分析表明,制动块形状因子越小,制动盘和制动块的温度越低；制动块形状因子越大,制动盘和制动块的温度越高。等面积制动块形状因子的提出为设计者提供了制动块形状设计的理论参考依据。
研究了结构和约束对制动盘和闸片振动模态的影响,制动盘边缘处结构的改变对制动盘每一阶频率的影响趋势基本一致,约束的改变对频率大于5000Hz以上的模态影响敏感,设计者可以根据实际测量的噪声频率范围,通过改变结构或约束的方法,避开噪声频率,达到减振降噪的目的；制动块排列方式改变后,各阶频率都不同程度的变化,频率越高,变化越大,在约束数量不变的情况下,将闸片钢背的约束影响半径由原来的5mm增大到10mm,闸片的模态频率也随之增加,10KHz以内的增加幅度较小,大于10KHz的增加幅度较大,所以设计者可以通过改变制动块的排列和增大约束半径范围的方式改变所关心的模态振动频率。
Brake disc and brake lining are the important components of high-speed train disc brake system. Based on numbers of relative references, basic brake element composed of brake disc and single brake pad is used as research object; basic brake element model is established by finite element software ABAQUS; the changing regularity of brake temperature field is researched by thermo-mechanical coupling method, and is proved by experiment; the concept of equal-area brake pad shape factor is proposed, and the modal analysis of brake disc and brake lining is carried out; the effect of structure and constraint on brake disc and brake lining is researched, thereby vibration damping and noise reduction are realized. On the basis of this, the temperature field simulation of brake disc and brake lining is carried out.
Fiction pair composed of common circular brake pad and brake disc is taken as research object, and simulation analysis of brake temperature field is carried out in the conditions of fixed speed and constant pressure. The simulation result shows that temperature variation curves of contact surfaces of brake disc and brake pad both have saw-toothed variation characteristic; the temperature field cloud picture of brake disc is in tail shape from start, and gradually passes to circle type, and finally spotted high-temperature areas are interconnected to form banding distribution. The temperature field cloud picture of brake pad is in tongue shape from start, and gradually becomes banded; temperature spreads to export direction, and finally radiates to the whole model along width direction. The experiment research of brake temperature field shows that the simulation temperature curve is identical to the experimental temperature curve. This indicates that the method for research using basic brake element model is feasible, and its result also reveals process essential characteristic.
The concept of equal-area brake pad shape factor is proposed for the first time, that is Fs=0.0174R·θ/L. The formula not only has key element of brake pad, but also has friction radius, thus, the interaction of friction pair can be fully reflected. The shape factor describes graphic attributes; equal-area shape factor can measure the shape difference of brake pad, and can also reflect different placing position on the brake disc. The simulation results show that the smaller the shape factor of brake pad is, the lower the temperature of brake disc and brake pad is; the larger the shape factor of brake pad is, the higher the temperature of brake disc and brake pad is. The equal-area brake pad shape factor provides theoretical reference basis of brake pad shape design for designers.
The effect of structure and constraint on brake disc and brake lining vibration modal is studied.the change of edge structure of brake disc structure has effects on each rank frequency of brake disc, and the effect trends are basically the same; the change of constraint is sensitive to modal effect with frequency more than 5000Hz. According to noise frequency range of actual measurement, designers can use the method of changing structure or constraint to avoid noise frequency, therefore, the purposes of vibration damping and noise reduction are achieved. After the arrangement of brake pad is changed, each rank frequency changes to some extent. In the condition of unchanged constraint quantity, the constraint effect radius of brake lining steel backing increases to 10mm from 5mm, and the modal frequency of brake lining also increases; the increase of modal frequency less than 10KHz is less, and the increase of modal frequency more than 10KHz is larger; therefore, designers can change concerned modal vibration frequency by changing arrangement of brake pad and the way of increasing constraint radius range.
以常用的圆形制动块与制动盘构成的摩擦副为研究对象,采用定速、恒压条件进行了制动温度场和接触压力的仿真分析。结果表明,制动盘和制动块的接触面温度变化曲线都呈现出锯齿状的变化特征,制动盘温度场云图由开始的尾巴形状,逐渐过渡到环带状,最后由斑点状高温区域相互连通而形成条带状分布。制动块温度场云图由开始的舌头状逐渐变为带状,温度向出口方向扩散,最后沿厚度方向辐射至整个模型上。制动温度场实验研究表明,模拟温度曲线和实验温度曲线趋势相同。说明使用“基本制动元”模型进行研究的方法是可行的,其结果也具有揭示过程本质特征的特点。
提出了制动块等面积形状因子的概念,并进行了公式推导,即Fs=0.0174R·θ/L表达式中既包含了制动块关键要素,又包含了摩擦半径,所以能够比较全面的反映摩擦副之间的相互作用。形状因子描述的是一类图形的属性,等面积形状因子可以衡量制动块形状的区别,也可反映其在制动盘上的摆放位置不同。仿真结果对比分析表明,制动块形状因子越小,制动盘和制动块的温度越低；制动块形状因子越大,制动盘和制动块的温度越高。等面积制动块形状因子的提出为设计者提供了制动块形状设计的理论参考依据。
研究了结构和约束对制动盘和闸片振动模态的影响,制动盘边缘处结构的改变对制动盘每一阶频率的影响趋势基本一致,约束的改变对频率大于5000Hz以上的模态影响敏感,设计者可以根据实际测量的噪声频率范围,通过改变结构或约束的方法,避开噪声频率,达到减振降噪的目的；制动块排列方式改变后,各阶频率都不同程度的变化,频率越高,变化越大,在约束数量不变的情况下,将闸片钢背的约束影响半径由原来的5mm增大到10mm,闸片的模态频率也随之增加,10KHz以内的增加幅度较小,大于10KHz的增加幅度较大,所以设计者可以通过改变制动块的排列和增大约束半径范围的方式改变所关心的模态振动频率。
Brake disc and brake lining are the important components of high-speed train disc brake system. Based on numbers of relative references, basic brake element composed of brake disc and single brake pad is used as research object; basic brake element model is established by finite element software ABAQUS; the changing regularity of brake temperature field is researched by thermo-mechanical coupling method, and is proved by experiment; the concept of equal-area brake pad shape factor is proposed, and the modal analysis of brake disc and brake lining is carried out; the effect of structure and constraint on brake disc and brake lining is researched, thereby vibration damping and noise reduction are realized. On the basis of this, the temperature field simulation of brake disc and brake lining is carried out.
Fiction pair composed of common circular brake pad and brake disc is taken as research object, and simulation analysis of brake temperature field is carried out in the conditions of fixed speed and constant pressure. The simulation result shows that temperature variation curves of contact surfaces of brake disc and brake pad both have saw-toothed variation characteristic; the temperature field cloud picture of brake disc is in tail shape from start, and gradually passes to circle type, and finally spotted high-temperature areas are interconnected to form banding distribution. The temperature field cloud picture of brake pad is in tongue shape from start, and gradually becomes banded; temperature spreads to export direction, and finally radiates to the whole model along width direction. The experiment research of brake temperature field shows that the simulation temperature curve is identical to the experimental temperature curve. This indicates that the method for research using basic brake element model is feasible, and its result also reveals process essential characteristic.
The concept of equal-area brake pad shape factor is proposed for the first time, that is Fs=0.0174R·θ/L. The formula not only has key element of brake pad, but also has friction radius, thus, the interaction of friction pair can be fully reflected. The shape factor describes graphic attributes; equal-area shape factor can measure the shape difference of brake pad, and can also reflect different placing position on the brake disc. The simulation results show that the smaller the shape factor of brake pad is, the lower the temperature of brake disc and brake pad is; the larger the shape factor of brake pad is, the higher the temperature of brake disc and brake pad is. The equal-area brake pad shape factor provides theoretical reference basis of brake pad shape design for designers.
The effect of structure and constraint on brake disc and brake lining vibration modal is studied.the change of edge structure of brake disc structure has effects on each rank frequency of brake disc, and the effect trends are basically the same; the change of constraint is sensitive to modal effect with frequency more than 5000Hz. According to noise frequency range of actual measurement, designers can use the method of changing structure or constraint to avoid noise frequency, therefore, the purposes of vibration damping and noise reduction are achieved. After the arrangement of brake pad is changed, each rank frequency changes to some extent. In the condition of unchanged constraint quantity, the constraint effect radius of brake lining steel backing increases to 10mm from 5mm, and the modal frequency of brake lining also increases; the increase of modal frequency less than 10KHz is less, and the increase of modal frequency more than 10KHz is larger; therefore, designers can change concerned modal vibration frequency by changing arrangement of brake pad and the way of increasing constraint radius range.
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