基于多物理场耦合仿真的盘式制动器制动性能的影响研究

Research on the Influence of Disk Brakes’ Braking Performance Based on Multi-Physical Field Coupling Simulation

摘要: 制动盘的制动性能受其材料与结构的显著影响。为探究其影响规律并实现性能优化，本研究采用计算流体动力学(CFD)与有限元相结合的仿真方法，构建了高速列车盘式制动器在紧急制动工况下的流–热–固多物理场耦合模型。通过对比努塞尔数理论值与模拟值，验证了模型对流换热系数预测的准确性，为后续分析奠定了基础。基于该模型，系统研究材料因素对制动盘制动性能的影响，选择对比了合金钢、低碳钢和铸铁三种材料制动盘的性能表现。研究发现，合金钢制动盘的综合性能最优，其温度峰值和应力峰值较低碳钢分别低8.7%和9.5%，且达到峰值的时间更早；与铸铁相比，其优势更为明显。此外，研究还发现，当采用挖槽结构时，不同材料制动盘之间的性能差异明显缩小。综上所述，本研究通过多物理场耦合仿真，揭示了材料对制动盘热力分布的影响机制，为制动盘的优化设计提供了理论依据与参考。

Abstract: The braking performance of a brake disc is significantly affected by its material and structure. In order to investigate the influence law and optimize the performance, this study adopts a simulation method combining computational fluid dynamics (CFD) and finite elements to construct a coupled flow-heat-solid multi-physical field model for high-speed train disc brakes under emergency braking conditions. By comparing the theoretical and simulated values of Nussell number, the accuracy of the model’s convective heat transfer coefficient prediction is verified, which lays the foundation for the subsequent analysis. Based on the model, the influence of material factors on the braking performance of brake discs is systematically investigated, and the performance of brake discs made of alloy steel, mild steel and cast iron is compared. It is found that alloy steel brake discs have the best overall performance, with their peak temperature and peak stress values lower than those of mild steel by 8.7% and 9.5% respectively, and reaching the peak value earlier; compared with cast iron, its advantage is more obvious. In addition, it was found that the performance difference between different materials of brake discs was significantly reduced when the grooved structure was used. In summary, this study reveals the influence mechanism of materials on the thermal distribution of brake discs through multi-physics field coupling simulation, which provides a theoretical basis and reference for the optimal design of brake discs.