1.IntroductionIntroduction 2.Objective and scopesObjective and scopes 3.Project flowProject flow 4.Literature reviewLiterature review 5.Previous workPrevious work 6.Contact analysisContact analysis 7.ResultResult 8.Structural modificationStructural modification 9.ConclusionConclusionCONTENTS

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

TO DETERMINE CONTACT PRESSURE DISTRIBUTION AND CONTACT AREA OF A DRUM BRAKE ASSEMBLY USING FINITE ELEMENT METHOD 2. OBJECTIVE 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

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

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

DRUMBRAKE SHOE BODYLINING Density (kg/m 3 ) Young's modulus (GPa) Poisson's ratio0.3 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 5. PREVIOUS WORK (PSM 1)

ComponentsTypes of elementNo. of elements No. nodes Drum Linear hexahedral elements (C3D8) Leading shoe Linear hexahedral elements (C3D8) Linear wedge element type (C3D6) Trailing shoe Linear hexahedral elements (C3D8) Linear wedge element type (C3D6) content FE model

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

6 Parameters were used to study the influence to contact analysis 1.Test condition 2.Coefficient of friction 3.Actuation pressure 4.Material properties (lining) 5.Material properties (brake shoe body) 6.Installation gap content CONTACT ANALYSIS

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

Static Dynamic CONTACT PRESSURE DISTRIBUTION FOR LEADING SHOE

Static Dynamic CONTACT PRESSURE DISTRIBUTION FOR TRAILING SHOE

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

CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT COEFFICIENT OF FRICTION (LEADING)

CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT COEFFICIENT OF FRICTION (TRAILING)

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

CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT ACTUATION PRESSURE (LEADING)

CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT ACTUATION PRESSURE (TRAILING)

The actual Elastic properties for lining is 3.10GPa CONTACT AREA WITH DIFFERENT MATERIAL PROPERTIES (LINING)

CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT MATERIAL PROPERTIES (LEADING)

CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT MATERIAL PROPERTIES (TRAILING)

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

CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT MATERIAL PROPERTIES (LEADING)

CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT MATERIAL PROPERTIES (TRAILING)

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

CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT INSTALLATION GAP (LEADING)

CONTACT PRESSURE DISTRIBUTION WITH DIFFERENT INSTALLATION GAP (TRAILING) content

PARAMETERCONTACT AREA CONTACT PRESSURE DISTRIBUTION COEFFICIENT OF FRICTIONVARY ACTUATION PRESSURENOVARY E LININGVARY E BRAKE SHOE BODYVARY INSTALLATION GAPVARY content Overall Results

STRUCTURAL MODIFICATION MODEL 1: Adjust location for leading lining MODEL 2: Adjust location for trailing lining MODEL3: Add more length for both shoe MODEL 4: Add thickness at shoe rib MODEL 5: Add thickness at shoe platform 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 2 Model 1 Model 3Model 4 Model 5 Current Model STRUCTURAL MODIFICATION (CTD)

MODEL SHOE12345 LEADING3.8%0-1.1%-5.4%7.2% TRAILING-7.3%-37%-0.2%-8.3%1.7% CONTACT AREA Figure :Contact area for different models Comparison base on current model

Trailing Leading MODEL 1

Trailing Leading MODEL 2

Trailing Leading MODEL 3

Trailing Leading MODEL 4

Trailing Leading contentMODEL 5

1.Only FE method are able to perform contact analysis both static and dynamic conditions. 2.Maximum contact pressure occurs at the actuation side for leading shoe and at the abutment side for trailing shoe. 3.Parameters that can influence the contact properties are coefficient of friction, material properties, actuation pressure and installation gap. 4.Structural modification can improve the contact area and pressure distribution. CONCLUSION

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