How to simulate heat generation in disc brakes in Calculix?

I am a student of Continuum Mechanics and I have to do my master thesis, I want to do a contact simulation in disc brake. As shown on the Comsol website.

Please help me reproduce similar results. I want the disc to rotate.

Thank you


how can we help you?
there should an example in the manual!?

i have there an example, but i don’t if these is usefull for you:


 ##   Structure: ring
 ##   Test objective: rotating ring & axisymmetric stress 
 PNT p0       0.00000        0.00000        0.00000
 PNT P001   100.00000        0.00000        0.00000
 PNT P002     0.00000      100.00000        0.00000
 PNT P003     0.00000       50.00000        0.00000
 PNT P004    50.00000        0.00000        0.00000
 PNT P005  -100.00000        0.00000        0.00000
 PNT P006   -50.00000        0.00000        0.00000
 PNT P007     0.00000     -100.00000        0.00000
 PNT P008     0.00000      -50.00000        0.00000
 LINE L001 P004 P001
 LINE L002 P001 P002 p0
 LINE L003 P002 P003
 LINE L004 P003 P004 p0
 LINE L005 P002 P005 p0
 LINE L006 P005 P006
 LINE L007 P006 P003 p0
 LINE L008 P005 P007 p0
 LINE L009 P007 P008
 LINE L010 P008 P006 p0
 LINE L011 P007 P001 p0
 LINE L012 P004 P008 p0 
 GSUR A001 - BLEND + L004 + L001 + L002 + L003
 GSUR A002 + BLEND + L003 - L007 - L006 - L005
 GSUR A003 - BLEND - L006 + L008 + L009 + L010 
 GSUR A004 - BLEND - L009 + L011 - L001 + L012 
 SETA ldivr l L001 L003 L006 L009
 COMP ldivr d
 SETA ldivt l L002 L004 L005 L007 L008 L010 L011 L012
 COMP ldivt d
 flip all
 DIV ldivr mult 20
 DIV ldivt mult 20
 ELTY all QU4S
 MESH all
 send all abq
 plot e all


 **   Structure: ring
 **   Test objective: rotating ring & axisymmetric stress
 **   radial displ ri 1624 ro 1425 tang. stress 6820 rad stress (ANSYS 799734)

Model: rotation ring








*SOLID SECTION, Elset=Eall, Material=steel,ORIENTATION=OR1







It should be possible to simulate that in CalculiX and might be even easier to realize than in COMSOL since you don’t have to imitate motion in pure heat transfer analysis like they do, you can actually simulate that motion using thermal stress analysis. So you will need transient coupled temp-disp simulation and *GAP HEAT GENERATION to include frictional heat generation.

This example from Abaqus documentation can help you since CalculiX uses very similar (mostly the same) keyword syntax:

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Thank you very much I will try it.

Thank you very much. I am reading about it. I will first start with meshing using Salome and then use Calculix launcher. Please, I hope you will guide me step by step.

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I recreated the model from Abaqus documentation for use in CalculiX (with some modifications to make it work in ccx). Unfortunately, it doesn’t fully converge yet - the pad starts deforming too much, maybe because of too coarse mesh (but that’s the one they used in Abaqus) or unavoidable differences between Abaqus and CalculiX analysis. However, you can see some rotation with heat being generated and it can be a good starting point.

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Thank you very much this is really amazing.

Depending on your final goal and point of interest you could also change your reference system and use a rotating heat source.
That would be a real hassle, but if you get it, your thesis supervisor would be pretty freaked out searching for the brake. :joy:


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