Developing an accurate finite element model for brake disc in contact with the pad using experimental modal analysis

The brake system is a critical safety component in cars, and its performance is essential for the safety of both the driver and passengers. The stability of the brake disc and understanding the contact area between the disc and the brake pads are crucial aspects of brake system design and performance. This paper aims to create an accurate model of the brake system, especially the contact area between the disc and the pads. This model can be used to investigate the effects of increasing braking pressure and changing the contact surface. Moreover, this model can calculate the dynamic responses of the system when an angular velocity is applied to the disc. First, a braking system was tested experimentally several times. Then a finite element model of the structure was created in ANSYS commercial software with defining suitable elements for the contact area between the disc and the pads. In the following, by an identification process a distribution of contact parameters at different braking pressures was obtained. The results shows that when the braking pressure increases, the dynamic responses of the structure increase, as well as the contact stiffness. A further increase in braking pressure does not have much effect on the contact stiffness and the contact area becomes like a new support.