Simulation of friction and wear for a low-steel brake material based on experimental pv-mapping of its basic constituents

The coefficient of friction (COF) and wear are critical parameters in assessing disc brake performance. However, their study is challenging due to their interdependence on contact pressure, sliding velocity, temperature, and material composition. The complex contact interactions between brake pads and discs involve the continuous formation and destruction of mesoscopic contact plateaus, which are highly influenced by individual pad constituents. To address this complexity, a mesoscale cellular automaton approach has been further developed to predict the impact of specific pad ingredients on brake performance. This method use COF and wear pressure-velocity maps of single pad ingredients derived from pin-on-disc (POD) tests. The findings of this study show that the simulated COF is qualitative in line with experimental data from dyno bench tests. However, an offset is observed between the simulated and experimental COF curves, likely due to differences in measurement methodologies between POD and inertia dynamometer bench tests. Additionally, the simulation provides insights into the evolution of the contact area during braking, offering a detailed analysis of the contribution of each raw material to its formation. Furthermore, it delivers critical information on the contact pressure each constituent can withstand, demonstrating, for instance, that metal fibres experience higher contact pressure than other ingredients, reaffirming their role as primary load carriers. The ability to predict these parameters early in the design phase is strategically advantageous, facilitating the development of friction pad materials and disc brake systems that optimize cost and time efficiency while advancing sustainability and environmental responsibility. • A CA approach was further developed to include the effect of single pad ingredients. • Experimental pressure-velocity maps for pad single ingredients are presented. • The CA tool predicted the coefficient of friction (COF) of a low-steel brake material. • A test cycle was simulated and compared with dyno bench tests. • The CA simulated COF was qualitatively in line with the experimental results.