Riassunto analitico
This research project is mainly concerned with analysis and study of contact forces influencing fluid leakage phenomenon in ECS brake calipers. The caliper belongs to commercial vehicles. It is desirable to discover new patterns in FEM modeling that would aid engineers in their future designs. This is done by creating a FE code written in Abaqus that can assess the contact pressure and forces distribution of a simplified caliper design, composed by only the main parts, under a load configuration that is almost identical to the one of the actual caliper. The experimental test results and a complete FEM model have been selected as starting point of the analysis. They allow to compare a completely new idea of brake caliper FEM modeling with reliable results and calculations. Following this, the model is generalized to other EPB calipers to understand the behavior of design parameters on the phenomenon. In the end, a rough estimation of safety factors in the different cases is performed to match the model results with experimental results. The modeling technique studied in this thesis work could be further developed and standardized for industrial applications.
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