International Journal of Science, Engineering and TechnologyAuthors: Shivani Baban Suryawanshi, Prof. Dr. T.Y badgujar
Abstract: Wear of the brake pad and rotor governs the durability, maintenance interval and reliability of passenger-car disc brakes. This paper presents a three-dimensional finite element (FE) framework for predicting wear at the pad–disc interface using a generalised form of Archard’s wear law integrated with an explicit Euler scheme. A front brake corner is decomposed using modular system modelling and reduced to a piston–back plate–friction lining–rotor subsystem, which is analysed in ANSYS with frictional surface-to-surface contact. Wear is updated iteratively over 2900 rotor revolutions (≈2500 m of sliding). Static normal loading (2.5 kN) produces a symmetric pressure peak of about 1.2 MPa beneath the piston rim, whereas tangential friction (μ = 0.45) shifts the pressure to the leading edge and causes trailing-edge separation; running-in then progressively levels the pressure field. Three lining materials—organic, semi-metallic and ceramic-matrix composite—are compared. Maximum wear depth falls from 15.0 µm to 6.2 µm and 2.1 µm, while running-in lengthens from 2400 to 4100 and 5800 revolutions and the initial peak pressure rises from 1.20 to 2.10 MPa, exposing a stiffness–wear trade-off. The framework offers a basis for experimental validation and pad design optimisation.
DOI: https://doi.org/10.5281/zenodo.24158090
