Virtual Wear Prediction of Alternative Brake Friction Composites using Finite Element Simulation

This study presents a modelling and simulation approach for predicting the wear of brake friction composites in automotive brake applications. Two alternative brake friction composites are compared for their wear performance through a virtual pin-on-disc mechanism. The pin specimens consist of two developed compositions: one with basalt fibre and calcium carbonate filler, and the other with aramid fibre and barium sulfate filler. Both have common ingredients like phenolic resin, graphite, and friction modifiers. Experimental pin-on-disc wear tests validate comparative wear performance of brake friction composites as per the finite element analysis findings. This indicates their capability for potential applications in automotive brake systems. The research also establishes a methodology for digital development of eco-friendly brake friction materials through optimal formulation of ingredients using Computer Aided Engineering (CAE). Major Findings: The aramid fibre-based brake composite exhibits superior wear resistance and friction performance compared to the basalt fibre-based composite. The finite element analysis results were validated by experimental pin-on-disc wear tests. These findings confirm the potential of these composites as eco-friendly alternatives for automotive brake applications.