Load-dependent Finite Element Wear Simulation of Semi-Metallic and Ceramic Friction Materials Using ANSYS

Ceramic brake pads are the most recent advancement in brake pad technology due to their high material quality, effectiveness, and longevity. This study contrasts ceramic brake material's friction and wear properties with copper-free semi-metallic ones. Semi-metallic and ceramic friction specimens' friction and wear behaviour have been experimentally studied and compared using FEM (finite element method) simulation using ANSYS software. A rotary pin-on-disc tribometer with ASTM G99 guidelines has been used to conduct the wear tests under various loading conditions, i.e. 40 N, 50 N, and 60 N, at a sliding speed of 2.19 m/s, and over a sliding distance of 6283 m. The trials were used to calculate the coefficient of friction (CoF) and wear of semi-metallic and ceramic pin materials. Since the augmented Lagrange approach has assertive convergence behaviour and nonlinear contact analysis, ANSYS transient structural utilized it to simulate the wear of the friction materials. The results of trials are contrasted with the material wear estimated from the models. The semi-metallic friction material was found to have more material wear and CoF than the ceramic friction material. Abrasive wear was the dominant wear mechanism at high loading conditions for both friction materials. Higher material wear was observed for both materials at 60 N load with increased CoF. At 60 N load, ceramic friction material performed better than semi-metallic friction material in terms of material wear. The outcomes of the simulation and experiment were found to be consistent and in agreement.

Automated summary

Ceramic brake pads are the most advanced brake pad technology with high quality, effectiveness, and longevity. This study compares the friction and wear properties of ceramic and copper-free semi-metallic brake materials using FEM simulation and wear tests. The results show that ceramic brake material has lower wear and coefficient of friction (CoF) compared to semi-metallic material. Both materials exhibit abrasive wear as the dominant wear mechanism under high loading conditions. At 60 N load, ceramic material outperforms semi-metallic in terms of wear. The simulation and experiment results are consistent and in agreement.