Abstract
Existing models describing the formation of heat cracks in heavy-duty vehicles are not detailed enough to predict the sensitivity of brake discs for heat cracks. In this paper, results from a dynamometer experiment are discussed. They allow a deeper understanding of the processes that result in the failure of brake discs. The experiment described is a standardized heat crack test, which was performed over 300 cycles and ended with a through-thickness crack. During the test, the brake disc was monitored via a thermographic camera, a pyrometer, two sliding thermocouples, a set of capacitive displacement sensors, and an eddy current crack detector. The results show that the current explanation model might not consider several factors that contribute to the crack propagation. Cyclic shear movements at the disc surface are observed, which are likely caused by the cooling channel pins. The variation of the coning of the disc correlates with the maximum disc surface temperature and the crack growth rate. The consequences of the observations are discussed to develop a more detailed model to explain the formation of heat cracks.
Similar content being viewed by others
References
Brezolin, A., Soares, M.R.F.: (2007) Influence of Friction Material Properties on Thermal Disc Crack Behavior in Brake Systems. Influence of friction material. In: SAE Brasil 2007 Congress and Exhibit. SAE International 400 Commonwealth Drive, Warrendale
Collignon, M., Cristol, A.-L., Dufrénoy, P., Desplanques, Y., Balloy, D.: Failure of truck brake discs: a coupled numerical–experimental approach to identifying critical thermomechanical loadings. Failure of truck brake discs. Tribol. Int. 59, 114–120 (2013). https://doi.org/10.1016/j.triboint.2012.01.001
Cristol, A., Collignon, M., Desplanques, Y., Dufrénoy, P., Balloy, D., Regheere, G.: Improvement of truck brake disc lifespan by material design. In: Transport Research Arena, Paris (2014)
Dufrénoy, P., Bodovillé, G., Degallaix, G.: Damage mechanisms and thermomechanical loading of brake discs. In: Petit, J., Rémy, L. (eds.) Temperature-fatigue interaction: SF2M, vol. 29, pp. 167–176. Elsevier, London (2002)
Gao, C.H., Huang, J.M., Lin, X.Z., Tang, X.S.: Stress analysis of thermal fatigue fracture of brake disks based on thermomechanical coupling. J. Tribol. 129, 536 (2007). https://doi.org/10.1115/1.2736437
Kim, D.-J., Lee, Y.-M., Park, J.-S., Seok, C.-S.: Thermal stress analysis for a disk brake of railway vehicles with consideration of the pressure distribution on a frictional surface. Mater. Sci. Eng. A. 483–484, 456–459 (2008). https://doi.org/10.1016/j.msea.2007.01.170
Le Gigan, G., Vernersson, T., Lunden, R., Skoglund, P.: Disc brakes for heavy vehicles: an experimental study of temperatures and cracks. Disc brakes for heavy vehicles. Proc. Inst. Mech. Eng. Part D J. Automob. Eng. 229, 684–707 (2015). https://doi.org/10.1177/0954407014550843
Poeste, T.: Untersuchungen zu reibungsinduzierten Veränderungen der Mikrostruktur und Eigenspannungen im System Bremse: Mikrostruktur und Eigenspannungen. Dissertation, Technische Universität Berlin (2005)
Rashid, A., Stromberg, N.: Sequential simulation of thermal stresses in disc brakes for repeated braking. Proc. Inst. Mech. Eng. Part J J. Eng. Tribol. 227, 919–929 (2013). https://doi.org/10.1177/1350650113481701
Sardá, A.: Wirkungskette der Entstehung von Hotspots und Heißrubbeln in Pkw-Scheibenbremsen. Dissertation, Technische Universität Darmstadt (2009)
Steffen, T., Bruns, R.: Hotspotbildung bei Pkw-Bremsscheiben. ATZ Automobiltech Z. 100, 408–413 (1998). https://doi.org/10.1007/BF03221499
Wiegemann, S.-E., Fecher, N., Merkel, N., Winner, H.: Automatic Heat Crack Detection of Brake Discs on the Dynamometer: EB2016-SVM-057. In: Eurobrake, Milan (2016)
Yamabe, J., Takagi, M., Matsui, T., Kimura, T., Sasaki, M.: Development of Disc Brake Rotors for Heavy- and Medium-Duty Trucks with High Thermal Fatigue Strength. In: International Truck and Bus Meeting & Exhibition, Fort Worth (2003)
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher’s Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Bilgic Istoc, S., Winner, H. Heat cracks in brake discs for heavy vehicles. Automot. Engine Technol. 3, 61–68 (2018). https://doi.org/10.1007/s41104-018-0027-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s41104-018-0027-y