Introduction Objective and scopes Project flow Literature review Previous work Contact analysis

2. CONTENTS • Introduction • Objective and scopes • Project flow • Literature review • Previous work • Contact analysis • Result • Structural modification • Conclusion

3. 1. 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

4. 2. OBJECTIVE “TO DETERMINE CONTACT PRESSURE DISTRIBUTION AND CONTACT AREA OF A DRUM BRAKE ASSEMBLY USING FINITE ELEMENT METHOD” SCOPES • 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

5. SMJ 5912 START START Generate FE model Run modal analysis FINISH FINISH Compare Modal Analysis Result Between Experimental and FE Method Perform Contact Analysis using validated model Purpose structural modification Error not exceed than 5% No Yes 3. PROJECT FLOW SMJ 5924 content

6. 4. LITERATURE REVIEW 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 Figure : Contact pressure distribution for leading and trailing shoes H-i Kang (2002) content

7. 5. PREVIOUS WORK(PSM 1) 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

8. FE model content

9. 6. CONTACT ANALYSIS Surface-to-surface contact interaction The drum surface are set as master surface The lining surface are set as slave surface Figure : Result obtain from FE software

10. CONTACT ANALYSIS • 6 Parameters were used to study the influence to contact analysis • Test condition • Coefficient of friction • Actuation pressure • Material properties (lining) • Material properties (brake shoe body) • Installation gap content

11. CONTACT AREA WITH DIFFERENTTEST CONDITION Contact area 5.5% larger for dynamic test condition for leading shoe Contact area are 27.1% smaller for trailing shoe.

12. CONTACT PRESSURE DISTRIBUTION FORLEADING SHOE Dynamic Static

13. CONTACT PRESSURE DISTRIBUTION FORTRAILING SHOE Dynamic Static

14. CONTACT AREA WITH DIFFERENTCOEFFICIENT OF FRICTION The higher value coefficient of friction, the lower contact area.

15. CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT COEFFICIENT OF FRICTION(LEADING)

16. CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT COEFFICIENT OF FRICTION(TRAILING)

17. CONTACT AREA WITH DIFFERENTACTUATION PRESSURE Contact area unchained for both shoes when different actuation pressure are applied. 85.7% for leading and 64.2% for trailing

18. CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT ACTUATION PRESSURE(LEADING)

19. CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT ACTUATION PRESSURE(TRAILING)

20. CONTACT AREA WITH DIFFERENTMATERIAL PROPERTIES(LINING) The actual Elastic properties for lining is 3.10GPa

21. CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT MATERIAL PROPERTIES(LEADING)

22. CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT MATERIAL PROPERTIES(TRAILING)

23. CONTACT AREA WITH DIFFERENTMATERIAL PROPERTIES(BRAKE SHOE BODY) The actual Elastic properties for brake shoe body is 250GPa

24. CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT MATERIAL PROPERTIES(LEADING)

25. CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT MATERIAL PROPERTIES(TRAILING)

26. CONTACT AREA WITH DIFFERENTINSTALLATION GAP Highest area for leading shoe at 2mm gap (85.8%) Highest area for trailing at 0.5mm gap (65.0%)

27. CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT INSTALLATION GAP(LEADING)

28. CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT INSTALLATION GAP(TRAILING) content

29. Overall Results content

30. STRUCTURAL MODIFICATION 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 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

31. STRUCTURAL MODIFICATION(CTD) Current Model Model 1 Model 2 Model 5 Model 3 Model 4

32. CONTACT AREA Figure :Contact area for different models Comparison base on current model

33. MODEL 1 Trailing Leading

34. MODEL 2 Trailing Leading

35. MODEL 3 Trailing Leading

36. MODEL 4 Trailing Leading

37. MODEL 5 Trailing Leading content

38. CONCLUSION • Only FE method are able to perform contact analysis both static and dynamic conditions. • Maximum contact pressure occurs at the actuation side for leading shoe and at the abutment side for trailing shoe. • Parameters that can influence the contact properties are coefficient of friction, material properties, actuation pressure and installation gap. • Structural modification can improve the contact area and pressure distribution.

39. THANK YOU