汽車碟式煞車碟盤熱變形分析及優化

多次制動後的汽車製動盤會遇到煞車盤過熱，過度的熱變形和損壞的問題。本論文研究利用ANSYS析軟體模擬車輛在制動過程中碟盤與來令片摩擦產生之溫度分佈以及對結構產生之影響。並且藉由田口法分別對於最低盤面錐度、最低溫度、最低塑性變形，進行極差分析。得到三個目標的參數優組合設計，並且與原始設計模型-數值比較，驗證優組合是否能達到設計目標。並且得到每個設變參數對於設計目標的敏感度，以利未來碟盤設計可以依照需求進行碟盤設計時，可有效分析與設變以減少開發的時間及成本。　　研究結果顯示:外部通風式碟盤以及內部通風式碟盤的最低溫度、最低的盤面錐度以及最低塑性變形的優組合，以及每一個設計參數對於目標值的敏感度，如圖3-1及圖3-2所示。並且依據各性能指標分析結果比較，得到兩種通風碟盤的最佳幾何設計模型，如圖3-3及3-5所示。外部通風式碟盤參數敏感度 1. 盤面錐度的敏感度為: T>S>M>W>V 2. 最高溫度的敏感度為: C>V>A>M>O 3. Hub轉角處塑性應變的參數敏感度為:B>T>S>J>L 4. 斷熱溝塑性應變的參數敏感度為:K>T>O>R>U 5. 盤面與通風道連接端塑性應變的參數敏感為: T>V>O>K>A 內部通風式碟盤參數敏感度 1. 盤面錐度的敏感度為: S>B>E>O>U 2. 最高溫度的敏感度為: S>A>U>B>T 3. Hub轉角處塑性應變的參數敏感度為: L>E>U>Q>J 4. 盤面與鎖點連接端塑性應變的參數敏感度為: O>E>V>U>N 5. 盤面與通風道連接端塑性應變的參數敏感為:O>U>P>W>Q 關鍵字: 煞車盤、田口法、熱變形

關鍵字

煞車系統；田口法；熱變形

並列摘要

An automobile discs after repeated braking will encounter the problems of overheat of the disc, excessive thermal deformation, and rupture. In this study, the ANSYS FEM software is used to simulate the temperature distribution caused by the friction between the disc and the pad during braking and the effect on the structure. The Taguchi method was used to optimize the disc design for the three design targets: the minimum disk taper, minimum disc temperature, and minimum plastic deformation. The parameter optimal combination design of the three objectives is obtained, and compared with the original design model-numerical value, it is verified whether the optimal combination can reach the design objective. Besides, the sensitivity of each setting parameter to the design target can be found, so that when the brake disc design can be designed accordingly, it can effectively analyze and countermeasure to reduce development time and cost. 　　The research results show that for external ventilated discs and internal ventilated discs, based on three design targets: minimum disc temperature, minimum disc taper, and minimum plastic deformation, the sensitivity of each design parameter to the target value is as follows: Parameter sensitivity of externally ventilated discs (refer to Figure 3-1 for symbol meaning) 1. The sensitivity of the disk taper is: T> S> M> W> V 2. The sensitivity of the disc temperature is: C> V> A> M> O 3. The sensitivity of the plastic strain at the corner of the Hub is: B> T> S> J> L 4. The sensitivity of the plastic strain of the thermal insulation trench is: K> T> O> R> U 5. The sensitivity of the plastic strain at the connection end of the disk surface and the ventilation duct is: T> V> O> K> A Sensitivity of internal ventilated disc parameters (see Figure 3-2 for meaning of symbols) 1. The sensitivity of the disk taper is: S> B> E> O> U 2. The sensitivity of the highest temperature is: S> A> U> B> T 3. The sensitivity of the plastic strain at the corner of Hub is: L> E> U> Q> J 4. The sensitivity of the plastic strain at the end of the connection between the disc surface and the lock point is: O> E> V> U> N 5. The sensitivity of the plastic strain at the connecting end of the disk and the ventilation duct is: O> U> P> W> Q Keywords: Brake disc, Taguchi method, Thermal deformation