3D Design and Surface Mapping of Disc Brake Pad for High Speed Train Using FEA

Recurrently, the increase in production of high-speed trains worldwide has become a confirmed fact. Seeking to use the high-speed trains locally to link the capital of Egypt “Cairo” with the new industrial cities has become a national requirement. Modeling 3D surface maps using finite element analysis (FEA) is one of the most important mechanical design tools for frictional parts to facilitate the manufacture of brake systems for heavy duty vehicles, especially high-speed trains due to difficult working conditions.

In this paper, we presented simulate 3D surface maps for proposed frictional material pad using FEA at certain design parameters and experimental result conductions. The typical surface characteristics of disc brake pad are compared with commonly used materials in railway and vehicle brakes in Egypt. The surface mapping of the pad materials are characterized by the analysis and distribution for profile deformation, stress as well as the thermal distribution at different thicknesses of the proposed brake pad. We also studied the safety factor of the proposed design. This work aims to explain the dynamic behavior phenomena to ensure the robustness of the proposed design to be studied to meet the standard requirements.