Dynamic analysis of disc brake and impact law of related parameters on braking torque

A modeling method of parameterized flexible virtual prototype of disc brake was provided by the united application of finite element modeling (FEM) and dynamics analysis method. A virtual prototype of disc brake was created, in which the rotor, backplates and brake pads are flexible parts. A typical dynamics analysis in condition of the fully loaded braking process at the initial velocity of 60 km/h was illustrated. Simulation results show a good consistency with practice and theoretical calculation. Based on this virtual prototype, the orthogonal experimental design (OED) was selected to study the impacts of pressing force and friction coefficients at the two sides of rotor on braking torque. The results show that braking torque increases with the increase of each factor, among which pressing force has the most important role, and the effects of two friction coefficients are very close. The sensitivity of braking torque to pressing force keeps changeless basically, but increases when friction coefficients increase.