Numerical analysis of novel SiC3D/Al alloy co-continuous composites ventilated brake disc

A novel ventilated shaft brake disc prepared by SiC3D/Al alloy co-continuous composites (SiC3D/Al, 3D means three-dimensional network structure) was presented in this study, which can effectively reduce the unspring weight of high-speed trains. The innovative concept is based on the use of a high temperature and low wear SiC foam material fill with a metal alloy, able either to improve friction and wear properties and to transmit, with a very high flow rate, the heat produced on the friction surface. In order to identify the geometric design and used material of this brake disc and secure braking stability, the numerical thermal and thermal stress investigations considering air cooling during emergency braking phase at the speed of 350 km/h were carried out using finite element (FE) and computational fluid dynamics (CFD) methods. The results showed that low temperature was obtained, as well as distributed uniformly on the brake disc, which attributes to high thermal conductivity of the disc material together with excellent cooling ability of the brake disc. During the braking phase, maximum thermal stress is 186.44 MPa, at 30 s, but the highest temperature is 471.08 °C, at 70 s, they behaved inconsistently in time. The maximum thermal stress is lower than the permitted stress of the disc material. The simulation results are consistent with the experimental dates well. The brake disc can meet the requirement of high-speed trains at 350 km/h.