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net/publication/303487478
Detailed Strength Analyses of Drum Brakes Used in Light and Heavy Duty
Trucks
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ÖZET
Kampanalı frenler uzun yıllardır temel çalışma ilkesinde önemli değişiklikler olmaksızın otomotiv
sektöründe kullanılmaktadır. Bununla birlikte, kampanalı frenlerin geliştirilmesi farklı araç tipleri ve araçlarda
bulunan farklı dingil tonajları için optimize bir tasarım elde edebilmek için devam eder. Bu çalışmada hafif ve
ağır vasıta kamyon kampanalı frenlerinin maksimum frenleme momentleri sırasında oluşan yapısal deformasyon
ve gerilim dağılımlarının sonlu elemanlar analizi (FEA) yazılımı kullanılarak incelemesi anlatılmıştır.
Maksimum frenleme momentleri araç özelliklerine göre kampana sabit, ileriye ve geriye doğru dönerken oluşan
kuvvetleri firma içinde geliştirilen, çok sayıda farklı araç test sonuçları ile doğrulanmış dâhili bir yazılım ile
hesaplanır. Analizlerde elde edilen gerilme değerleri firmaya ait malzeme veri tabanındaki sınırlarına göre
değerlendirilir. Bu çalışma da ayrıca farklı cıvata modelleme teknikleri gibi simülasyondaki yapısal
değişikliklerin gerilim değerleri ve dağılımı üzerine etkileri gösterilerek gerçekçi model oluşturmanın önemi
vurgulanmaya çalışılmıştır.
Anahtar kelimeler: Fren sistemleri, Kampanalı fren, Sonlu Elemanlar Metodu, Mukavemet analizi.
ABSTRACT
The drum brakes are used for many years in the automotive industry without significant changes in the main
working principle. However, the development of drum brakes continues in order to have the optimized design
for different tonnages of axles and different types of vehicles. This paper aims to analyze structural deformation
and stress concentration of drum brakes in light and heavy-duty truck (LDT & HDT) during the maximum
braking torques by employing commercial finite element analysis (FEA) software. These maximum braking
torques in the cases of stationary drum, drum rotating forwards and backwards used in FE-Analyses are
calculated with an in-house software, which was verified with testing results of numerous different vehicles. The
obtained stress values are evaluated based on the limits in the material database of the company. This paper also
highlights the effects of different modeling techniques on the stress concentration of drum brake components by
comparing the results of different bolt models.
Keywords: Brake systems, Drum brake, Finite Element Model, Strength analysis.
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• It should be able to be accommodated within convergence of the simulation without redefining
the wheel space available. all of the related sets. With pre-processor part of
• It should have well anti wear properties. Abaqus-CAE, it is possible to define the sets of
• It should allow the optimum rate of heat contacts, interactions and connections directly on
transfer. the geometry. The model has over 400.000
elements and over 600.000 nodes.
The brake drum is usually made from cast iron The drum brake is calculated with geometrical
and essentially a cylinder sandwiched between the nonlinearities in order to increase the accuracy. The
wheel rim and the wheel hub. Inside the drum, linear isotropic material behavior without plasticity
brake shoes lines are covered with friction material. is taken into account during the simulation. The
The brake shoes are pressed against the inside of brake pads are modeled with anisotropic material
the drum surface by a cam or actuators inside the behavior. The bolts on the brake drum and brake
wheel cylinders. The inside surface of the drum is carrier are also modeled and the pretension forces
acted upon by the linings of the brake shoes. When of these bolts are applied with friction in the first
the brakes are applied, the brake shoes are forced to steps of the simulation. The contact definitions are
come into contact with the inside surface of the in a very high amount at a drum brake model and
brake drum to stop or slow the rotation of the wheel mostly defined with surface smoothing because of
due to friction [7]. The hub is connected to the circular parts. In Figure 2, the component finite
drum by set of bolts and to the rim holding the tire element model of a HDT 4x2 case study is shown.
by the same set of bolts. The hub and the rim take
the load while driving, whereas the drum and the
rim are loaded while braking [8]. Figure 1 shows a
typical brake drum assembly.
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is fixed from the axle connection points. The drum 𝑟𝑟𝑠𝑠−𝑐𝑐𝑐𝑐𝑐𝑐 : 𝑠𝑠 − 𝑐𝑐𝑐𝑐𝑐𝑐 𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟
brake assembly on actual LDT 4x2 is shown in 𝐹𝐹𝑁𝑁 ∶ 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 𝑐𝑐ℎ𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 𝑓𝑓𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 𝑎𝑎𝑎𝑎 𝑛𝑛𝑛𝑛𝑛𝑛. 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝
Figure 3 for front axle and Figure 4 for rear axle. 𝑃𝑃𝑁𝑁 ∶ 𝑛𝑛𝑛𝑛𝑛𝑛. 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝
𝑝𝑝𝑒𝑒𝑒𝑒𝑒𝑒 ∶ 𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝
𝜂𝜂 ∶ 𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒
∗
𝐶𝐶 ∶ 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓
𝑟𝑟𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 ∶ 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 𝑟𝑟𝑟𝑟𝑟𝑟𝑖𝑖𝑢𝑢𝑢𝑢
g ∶ 𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎
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cases are scaled with the material limits as shown in
Figure 8. The brake chamber type is considered as
30 and a maximum pressure of 10 bar.
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limits. result comparison of the brake components for
original and simplified bolt geometries are shown
in Figure 11. The brake chamber type is considered
as 30 and a maximum pressure of 10 bar. The
results are scaled with the material limits.
7. CONCLUSION
This paper presents the structural analysis
methodology of drum brakes used in light and
heavy duty vehicles. FE-modeling of drum brake
with Abaqus-CAE is explained in details and the
loading conditions in FE-analysis are shown. Also,
the material database for drum brakes is presented
in order to explain the evaluation of stress values
from the simulation. The limits for the materials
used in the drum brake structure are obtained from
dynamometer testing. The effects of temperature on
the material are evaluated indirectly by
incorporating testing results.
The methodology is utilized for an example rear
Figure 10. Simplified bolt geometries for drum
axle drum brake used in LDT 4x2 vehicles. The
brake stress comparison analysis.
stress values of different components (drum brake,
This study focuses not on the bolt but instead on brake chamber and brake shoe) are shown. Also,
how the stress and strain states in the brake two different brake chamber types in three different
components can be accurately determined. The actuation pressure are compared in a table. The
modifications in the bolt and the nut certainly cause stress values above the limits are explained with the
error in the calculated values of stress in the brake low stiffness of the structure, and it is advised that
components because they affect the stiffness the stiffness of drum brake could be improved by
properties of the bolt–nut assembly. The stress reinforcing the brake shoe geometries.
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In the last section, a simplified finite element
bolt models are developed and then compared with
the full model with regard to the solution accuracy
of stresses. It is shown that the modelling technique
of the bolts play a significant role for the evaluation
of the drum brake components.
ACKNOWLEDGEMENTS
The authors gratefully acknowledge the support
given by Team Brake Systems, Stuttgart in carrying
out this investigation and realization of this article
in proceedings.
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