Using Finite Element Analysis to Predict the Brake Pressure Needed for Effective Rotor Cleaning in Disc Brakes

This paper presents an approach to simulating wear on both contact surfaces at the pad-to-rotor interface in disc brakes using general purpose finite element software. It represents a first step toward a method of simulating the brake pressure needed to effectively clean the rotor of unwanted oxide layers. Two simulation cases are presented. The first addresses running-in wear under constant load and corresponds to repeated brake applications at the same constant brake load. The second studies what will happen if a lower load is applied after the contact surfaces have been run-in at a higher load level. This lower load is applied to wear off an oxide layer after a sequence of repeated stop braking at higher load levels.