Title: Contact stiffness modelling and analysis of brake disc with rough geometrical topography and manufacturing deviation

Authors: Hehe Kang; Xiang Liu; Qiaolei Hu; Xuan Liu; Huali Han; Yongcheng Long; Haizhou Yuan

Addresses: School of Mechanical and Electrical Engineering, Zhoukou Normal University, Zhoukou, 466001, China ' School of Automobile Engineering, Guilin University of Aerospace Technology, Guilin, 541004, China ' School of Mechanical and Electrical Engineering, Zhoukou Normal University, Zhoukou, 466001, China ' School of Mechanical and Electrical Engineering, Zhoukou Normal University, Zhoukou, 466001, China ' School of Mechanical and Electrical Engineering, Zhoukou Normal University, Zhoukou, 466001, China ' State Key Laboratory of Vehicle NVH and Safety Technology, China Automotive Engineering Research Institute Co., Ltd., Chongqing, 401122, China ' School of Mechanical and Electrical Engineering, Zhoukou Normal University, Zhoukou, 466001, China

Abstract: Contact stiffness plays an important role in braking efficiency, braking squeal, and vibration response of brake system. However, randomness of manufacturing deviations caused in manufacturing process can lead to unsteadiness of the contact stiffness. To investigate the quantitative relationship between manufacturing tolerance and fluctuation of the contact stiffness, a contact stiffness model of brake disc is established through statistical rough contact theory and nonlinear stuck-slipped spring element, and then its effectiveness is validated by experimental data. Based on the model, a comprehensive analysis of various types of manufacturing deviations is conducted. The result shows that both normal and tangential initial contact stiffness are weakened by angular deviation and positively associated with positional deviation. This paper provides a novel way to reveal the inner mechanical relationship between macro-micro topography and initial contact stiffness of brake disc, which is significant for guiding tolerance design and performance optimisation of the brake system.

Keywords: manufacturing deviation; brake disc; rough interface; contact stiffness; normal contact; microscopic topography; stuck-slipped behaviour.

DOI: 10.1504/IJVSMT.2025.145564

International Journal of Vehicle Systems Modelling and Testing, 2025 Vol.19 No.1, pp.47 - 73

Received: 16 Oct 2024
Accepted: 25 Dec 2024
Published online: 04 Apr 2025 *