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Numerical analysis and testing of a new segmented brake disc fixed to the wheel of a wheelset

Sawczuk Wojciech, Jüngst Mateusz

Problemy Kolejnictwa

2019

Z. 183

121--135

In electric multiple units due to the existence of the wheelsets, the brake discs are mounted on wheels of wheelsets. Although the braking of the vehicle is carried out mainly using an electrodynamic brake, depending on the type of braking implemented, a friction brake is additionally used in some braking phases. In the operation of driving wheelsets, the wear of the friction surface of the disc to the limit dimension occurs faster than the wear of the wheel rim. As a consequence, in the case of replacing full discs, it is necessary to squeeze the wheels from the axles of the wheelset, assemble the discs and press the wheels on the axle again. Squeezing and re-pressing the wheel due to the scratching of the axle surface is not possible to be repeated. For this reason, brake disc manufacturers offer split disks that enable their assembly without extrusion of the wheel from the axis of the wheelset. Thus, there is no need to roll the wheelset out of the trolley frame. The article presents the construction of a new segment brake disk after testing on an inertia brake station for testing railway disc and block brakes based on Polish standards [2, 3]. With regard to the disc’s construction itself, a new technology for its implementation has been proposed. Most brake discs are produced by casting and finishing machining. In the case of the proposed brake disc, the prototype of the disc was made by welding the venting elements with the disc’s friction plate. The proposed brake disc was created during the implementation of the LIDER V project financed from the National Center for Research and Development in Warsaw.