Piston Retraction-Induced Braking Drag Mechanism of Commercial Vehicle Disc Brake Under Dynamic Working Conditions

Braking drag is a typical fault of brake systems, and clarifying the correlation mechanism between vehicular working conditions and braking drag is critical for brake design improvement. Based on fluid mechanics and contact mechanics, this paper establishes a dynamic model for braking drag mechanism analysis, combined with the return mechanism and force-bearing state of brake pistons. Firstly, a commercial vehicle brake system dynamic model is built via Amesim, and piston sliding resistance is identified as the key factor leading to insufficient piston retraction through user operational data analysis. Subsequently, a fluid-structure interaction-based dynamic coupling model of drag mechanism is established, typical braking conditions are extracted via K-means clustering, and piston friction, displacement and drag torque are solved with the system model outputs as inputs. Finally, drag-prone working conditions are determined, and the disc brake drag mechanism is revealed. The results show that piston sliding resistance is the primary factor in braking drag; medium-low speed prolonged braking has high drag susceptibility; and the seal contact area is in mixed lubrication, with contact pressure and friction dominated by asperity shear stress. This work enables accurate identification of drag-prone conditions, providing guidance for brake system optimization.