1. Introduction2. Objective and scopes3. Project flow4. Literature review5. Previous work6. Contact analysis7. Result8. Structural modification9. Conclusion

CONTENTSCONTENTS

1. INTRODUCTION1. INTRODUCTION

• Contact analysis is normally performed on brake assembly to study the pressure distribution and the contact area.

• Significant of contact analysis are to investigate the effect of contact problem to the wear, thermal and squeal.

• Only Finite Element Method are able to use to perform contact analysis both static and dynamic conditions.

content

“TO DETERMINE CONTACT PRESSURE DISTRIBUTION

AND CONTACT AREA OF A DRUM BRAKE ASSEMBLY

USING FINITE ELEMENT METHOD”

2. OBJECTIVE2. OBJECTIVE

SCOPESSCOPES

Develop a Finite Element model of drum brake. Validate the Finite Element model against experimental

result using modal analysis. Perform contact analysis using a commercial

Finite Element (FE) software package. Propose structural modification method in order to

determine uniform contact pressure distribution and

higher contact area.

content

3. PROJECT FLOW

Generate FE model

Run modal analysis

Compare Modal Analysis Result

BetweenExperimental and

FE Method

No

Yes

Error notexceed than

5%

START

FINISH

SMJ 5912

PerformContact Analysis using

validated model

Purposestructural modification

START

FINISH

SMJ 5924

content

The FE model validated by using modal analysis

Contact pressure at leading shoe are more higher than trailing shoe.

Parameters that can influence contact analysis are:

Coefficient of friction

Material properties

Actuation pressure

Rotation speed

Installation gap

4. LITERATURE REVIEW4. LITERATURE REVIEW

Figure : Contact pressure distribution for leading and trailing shoes H-i Kang (2002) content

  DRUM BRAKE SHOE BODY LINING

Density (kg/m3) 7673 8762 2638

Young's modulus (GPa) 104 250 3.1

Poisson's ratio 0.3 0.3 0.3

Three components of drum brake assembly are generated (Drum, leading shoe and trailing shoe)

FE model are validated using the experimental data (Modal analysis)

Material properties for the model are listed below

5. PREVIOUS WORK(PSM 1)

Components Types of element No. of elements

No. nodes

DrumLinear hexahedral

elements(C3D8)

7546 13578

Leading shoe

Linear hexahedral elements

(C3D8)Linear wedge

element type (C3D6)

1023 2776

Trailing shoe

Linear hexahedral elements

(C3D8)Linear wedge

element type (C3D6)

1130 2042

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FE modelFE model

Surface-to-surface contact interaction

The drum surface are set as master surface

The lining surface are set as slave surface

6. CONTACT ANALYSIS

Figure : Result obtain from FE software

6 Parameters were used to study the influence to contact analysis

1. Test condition

2. Coefficient of friction

3. Actuation pressure

4. Material properties (lining)

5. Material properties (brake shoe body)

6. Installation gap

content

CONTACT ANALYSISCONTACT ANALYSIS

0

10

20

30

40

50

60

70

80

90

100C

on

tact

are

a (%

)

Static Dynamic

Test condition

Contact area for different drum condition

Leading

Trailing

CONTACT AREA WITH DIFFERENTCONTACT AREA WITH DIFFERENTTEST CONDITIONTEST CONDITION

Contact area 5.5% larger for dynamic test condition for leading shoe

Contact area are 27.1% smaller for trailing shoe.

011

2232

4354

6575

8697

0.0E+00

1.0E+05

2.0E+05

3.0E+05

4.0E+05

5.0E+05

6.0E+05

Co

nta

ct P

ress

ure

(P

a)

Angular position (o)

Contact Pressure distribution at static condition(Leading)

Actuation side

Abutment side

Lining width

011

2232

4354

6575

8697

0.0E+00

1.0E+05

2.0E+05

3.0E+05

4.0E+05

5.0E+05

6.0E+05

Co

nta

ct P

ress

ure

(P

a)

Angular Position (o)

Abutment side

Lining width

Actuation side

Static

Dynamic

CONTACT PRESSURE DISTRIBUTION FORCONTACT PRESSURE DISTRIBUTION FORLEADING SHOELEADING SHOE

01

02

0

31

41

51

61

72

82

92

10

2

0.0E+00

1.0E+05

2.0E+05

3.0E+05

4.0E+05

5.0E+05

6.0E+05

Co

nta

ct

Pre

ssu

re (

Pa

)

Angular position (o)

Abutment side

Lining width

Actuation side

010

20

31

41

51

61

72

82

92

102

0.0E+00

1.0E+05

2.0E+05

3.0E+05

4.0E+05

5.0E+05

6.0E+05

Co

nta

ct P

ress

ure

(P

a)

Angular Position (o)

Abutment side

Actuation side

Lining width

Static

Dynamic

CONTACT PRESSURE DISTRIBUTION FORCONTACT PRESSURE DISTRIBUTION FORTRAILING SHOETRAILING SHOE

0

10

20

30

40

50

60

70

80

90

100C

on

tact

are

a (%

)

0.20 0.25 0.30 0.35 0.40

Coefficient of Friction

Leading

Trailing

CONTACT AREA WITH DIFFERENTCONTACT AREA WITH DIFFERENTCOEFFICIENT OF FRICTIONCOEFFICIENT OF FRICTION

The higher value coefficient of friction, the lower contact area.

0.0E+00

1.0E+05

2.0E+05

3.0E+05

4.0E+05

5.0E+05

6.0E+05

0 20 40 60 80 100

Angular position (O)

Co

nta

ct P

ress

ure

(P

a)

0.20

0.25

0.30

0.35

0.40

Actuation side Abutment side

μ

CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT COEFFICIENT OF FRICTIONCOEFFICIENT OF FRICTION

(LEADING)(LEADING)

0.0E+00

1.0E+05

2.0E+05

3.0E+05

4.0E+05

5.0E+05

6.0E+05

0 20 40 60 80 100

Angular position (O)

Co

nta

ct P

ress

ure

(P

a)

0.20

0.25

0.30

0.35

0.40

Actuation side

Abutment side

μ

CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT COEFFICIENT OF FRICTIONCOEFFICIENT OF FRICTION

(TRAILING)(TRAILING)

50

55

60

65

70

75

80

85

90

95

100

Co

nta

ct

are

a (

%)

2.0 2.5 3.0 3.5 4.0

Actuation Pressure (Mpa)

Leading

Trailing

Contact area unchained for both shoes when different

actuation pressure are applied.

85.7% for leading and 64.2% for trailing

CONTACT AREA WITH DIFFERENTCONTACT AREA WITH DIFFERENTACTUATION PRESSUREACTUATION PRESSURE

0.0E+00

1.0E+05

2.0E+05

3.0E+05

4.0E+05

5.0E+05

6.0E+05

7.0E+05

8.0E+05

9.0E+05

0 20 40 60 80 100

Angular position (o)

Pre

ssu

re D

istr

ibu

tio

n (

Pa)

2 MPa

2.5MPa

3 MPa

3.5 MPa

4 MPa

Actuation side Abutment side

CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT ACTUATION PRESSUREACTUATION PRESSURE

(LEADING)(LEADING)

0.0E+00

1.0E+05

2.0E+05

3.0E+05

4.0E+05

5.0E+05

6.0E+05

7.0E+05

8.0E+05

9.0E+05

0 20 40 60 80 100

Angular position (o)

Pre

ss

ure

Dis

trib

uti

on

(P

a) 2 MPa

2.5MPa

3 MPa

3.5 MPa

4 MPa

Actuation side Abutment side

CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT ACTUATION PRESSUREACTUATION PRESSURE

(TRAILING)(TRAILING)

50

55

60

65

70

75

80

85

90

95

100

Co

nta

ct

are

a (%

)

-15

%

-10

%

-5%

base

line

5% 10%

15%

Variation (%)

Leading

Trailing

The actual Elastic properties for lining is 3.10GPa

CONTACT AREA WITH DIFFERENTCONTACT AREA WITH DIFFERENTMATERIAL PROPERTIESMATERIAL PROPERTIES

(LINING)(LINING)

0.0E+00

1.0E+05

2.0E+05

3.0E+05

4.0E+05

5.0E+05

6.0E+05

0 8 16 24 32 40 48 57 65 73 81 89 97 105

Angular position (o)

Co

nta

ct P

rees

sure

(P

a)

-15%

-10%

-5%

baseline

5%

10%

15%

Actuation side Abutment side

CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT MATERIAL PROPERTIESMATERIAL PROPERTIES

(LEADING)(LEADING)

0.0E+00

1.0E+05

2.0E+05

3.0E+05

4.0E+05

5.0E+05

6.0E+05

0 8 16 24 32 40 48 57 65 73 81 89 97 105

Angular position (o)

Co

nta

ct P

rees

sure

(P

a)

-15%

-10%

-5%

baseline

5%

10%

15%

Actuation side Abutment side

CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT MATERIAL PROPERTIESMATERIAL PROPERTIES

(TRAILING)(TRAILING)

50

55

60

65

70

75

80

85

90

95

100

Co

nta

ct a

rea

(%)

-15%

-10% -5

%

base

line

5% 10%

15%

Variation (%)

Leading

Trailing

CONTACT AREA WITH DIFFERENTCONTACT AREA WITH DIFFERENTMATERIAL PROPERTIESMATERIAL PROPERTIES(BRAKE SHOE BODY)(BRAKE SHOE BODY)

The actual Elastic properties for brake shoe body is 250GPa

0.0E+00

1.0E+05

2.0E+05

3.0E+05

4.0E+05

5.0E+05

6.0E+05

0 10 20 31 41 51 61 72 82 92

Angular position (o)

Co

nta

ct P

rees

sure

(P

a)

-15%

-10%

-5%

baseline

5%

10%

15%

Actuation side Abutment side

CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT MATERIAL PROPERTIESMATERIAL PROPERTIES

(LEADING)(LEADING)

Contact Pressure distribution with different modulus of elasticity(Leading shoe body)

0.0E+00

1.0E+05

2.0E+05

3.0E+05

4.0E+05

5.0E+05

6.0E+05

0 10 20 31 41 51 61 72 82 92 102

Angular position (o)

Co

nta

ct P

rees

sure

(P

a)

-15%

-10%

-5%

baseline

5%

10%

15%

Actuation side Abutment side

CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT MATERIAL PROPERTIESMATERIAL PROPERTIES

(TRAILING)(TRAILING)

50

55

60

65

70

75

80

85

90

95

100

Co

nta

ct a

rea

(%)

0 m

m

0.5

mm

1.0

mm

1.5

mm

2.0.

mm

Installation gap

Leading

Trailing

CONTACT AREA WITH DIFFERENTCONTACT AREA WITH DIFFERENTINSTALLATION GAPINSTALLATION GAP

Highest area for leading shoe at 2mm gap (85.8%)

Highest area for trailing at 0.5mm gap (65.0%)

0.0E+00

1.0E+05

2.0E+05

3.0E+05

4.0E+05

5.0E+05

6.0E+05

0 20 40 60 80 100

Angular position (o)

Co

nta

ct

Pre

ssu

re (

Pa

)

0.5 mm

1.0 mm

1.5 mm

2.0 mm

0 mm

Actuation side Abutment side

CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT INSTALLATION GAPINSTALLATION GAP

(LEADING)(LEADING)

0.0E+00

1.0E+05

2.0E+05

3.0E+05

4.0E+05

5.0E+05

6.0E+05

0 20 40 60 80 100

Angular position (o)

Co

nta

ct P

ress

ure

(P

a)

0.5 mm

1.0 mm

1.5 mm

2.0 mm

0 mm

Actuation side Abutment side

CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT INSTALLATION GAPINSTALLATION GAP

(TRAILING)(TRAILING)

content

PARAMETER CONTACT

AREA

CONTACT

PRESSURE DISTRIBUTION

COEFFICIENT OF FRICTION VARY VARY

ACTUATION PRESSURE NO VARY

E LINING VARY VARY

E BRAKE SHOE BODY VARY VARY

INSTALLATION GAP VARY VARY

content

Overall ResultsOverall Results

STRUCTURAL MODIFICATION

MODEL 1 : Adjust location for leading lining

MODEL 2 : Adjust location for trailing lining

MODEL 3 : Add more length for both shoe

MODEL 4 : Add thickness at shoe rib

MODEL 5 : Add thickness at shoe platform

Structural modification done to

“Obtain more uniform pressure distribution by seeking greater contact area and lower pressure”

Greater contact area and uniform pressure distribution can reduce the uneven wear and squeal.

Structural modification done by changing the current geometry

Model 2 Model 1

Model 3 Model 4 Model 5

Current Model

STRUCTURAL MODIFICATION(CTD)

0

10

20

30

40

50

60

70

80

90

100

Co

nta

ct

are

a (

%)

Curr

en

t

Mo

de

l 1

Mo

de

l 2

Mo

de

l 3

Mo

de

l 4

Mo

de

l 5

MODEL

SHOE 1 2 3 4 5

LEADING 3.8% 0 -1.1% -5.4% 7.2%

TRAILING -7.3% -37% -0.2% -8.3% 1.7%

CONTACT AREACONTACT AREA

Figure :Contact area for different models

Comparison base on current model

010

2131

41

51

62

72

82

93

0.0E+00

1.0E+05

2.0E+05

3.0E+05

4.0E+05

5.0E+05

6.0E+05

Co

nta

ct P

ress

ure

(P

a)

Angular Position (o)

Actuation side

Abutment side

Lining width

010

2131

41

51

62

72

82

93

0.0E+00

1.0E+05

2.0E+05

3.0E+05

4.0E+05

5.0E+05

6.0E+05

Co

nta

ct P

ress

ure

(P

a)Angular Position (o) Lining width

Abutment side

Actuation side

Trailing

Leading

MODEL 1MODEL 1

010

2131

4152

6272

8393

0.0E+00

1.0E+05

2.0E+05

3.0E+05

4.0E+05

5.0E+05

6.0E+05

Co

nta

ct P

ress

ure

(P

a)

Angular Position (o)

Lining width

Abutment side

Actuation side

010

21

31

41

52

62

72

83

93

0.0E+00

1.0E+05

2.0E+05

3.0E+05

4.0E+05

5.0E+05

6.0E+05

Co

nta

ct P

ress

ure

(P

a)Angular Position (o)

Lining width

Abutment side

Actuation side

Trailing

Leading

MODEL 2MODEL 2

0

10

21

31

42

52

63

73

84

94

0.0E+00

1.0E+05

2.0E+05

3.0E+05

4.0E+05

5.0E+05

6.0E+05

Co

nta

ct

Pre

ss

ure

(P

a)

Angular Position (o)

Leading shoe 5-1

Actuation side

Abutment side

Lining width

010

21

31

42

52

63

73

84

94

0.0E+00

1.0E+05

2.0E+05

3.0E+05

4.0E+05

5.0E+05

6.0E+05

Co

nta

ct P

ress

ure

(P

a)Angular Position (o)

Actuation side

Abutment side

Lining width

Trailing

Leading

MODEL 3MODEL 3

010

20

31

41

51

61

71

82

92

102

0.0E+001.0E+052.0E+053.0E+054.0E+055.0E+056.0E+057.0E+05

8.0E+05

9.0E+05

1.0E+06

Co

nta

ct P

ress

ure

(P

a)

Angular Position (o)

Actuation side

Abutment side

Lining width

010

20

31

41

51

61

71

82

92

102

0.0E+001.0E+052.0E+053.0E+054.0E+055.0E+056.0E+057.0E+05

8.0E+05

9.0E+05

1.0E+06

Co

nta

ct P

ress

ure

(P

a)

Angular Position (o)

Actuation side

Abutment side

Lining width

Trailing

Leading

MODEL 4MODEL 4

0 816 24 31 39

4755

63

71

79

86

94

102

0.0E+00

1.0E+05

2.0E+05

3.0E+05

4.0E+05

5.0E+05

6.0E+05

Co

nta

ct P

ress

ure

(P

a)

Angular Position (o)

Actuation side

Abutment side

Lining width

0 81

62

43

13

94

75

56

3

71

79

86

94

10

2

0.0E+00

1.0E+05

2.0E+05

3.0E+05

4.0E+05

5.0E+05

6.0E+05

Co

nta

ct

Pre

ss

ure

(P

a)

Angular Position (o)

Actuation side

Abutment side

Lining width

Trailing

Leadingcontent

MODEL 5MODEL 5

1. Only FE method are able to perform contact analysis both static and dynamic conditions.

2. Maximum contact pressure occurs at the actuation side for leading shoe and at the abutment side for trailing shoe.

3. Parameters that can influence the contact properties are coefficient of friction, material properties, actuation pressure and installation gap.

4. Structural modification can improve the contact area and pressure distribution.

CONCLUSIONCONCLUSION

THANK YOU