In this study, numerical optimisation and experimental validation of a divided rail freight brake disc crown made of grey cast iron EN-GJL-250 is presented. The analysed brake disc is used in rail freight wagons and possesses a load capacity of 22.5 tons per axle. Two of the divided rail freight brake discs are mounted on each axle. With the aid of numerical analysis, the thermal dissipation properties of the brake disc were optimised and ventilation losses were reduced, and the numerical results were compared with experimental results. A one-way fluid–structure interaction analysis was performed. A computational fluid dynamic model of a divided rail freight brake disc, used to predict air flow properties and heat convection, was incorporated into a finite element model of the disc and used to evaluate the temperature of the disc. A numerical parametrical optimisation of cooling ribs of the brake disc was also performed, and novel optimised cooling ribs were developed. A transient thermal numerical analysis of the brake disc was validated using temperature measurements obtained during a braking test on a test bench. The ventilation losses of the brake disc were measured on a test bench specifically designed for the task, and the losses were compared to the simulation results. The experimentally obtained ventilation losses and temperature measurements compared favourably with the simulation results, confirming that this type of simulation process may be confidently applied in the future. Through systematic optimisation of the divided rail freight brake disc, ventilation losses were reduced by 37% and the mass was reduced by 21%, resulting in better thermal performance that will bring with it substantial energy savings.

中文翻译：

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分割式铁路货运制动盘冠的数值优化与实验验证

本研究提出了灰铸铁EN-GJL-250制成的分开式铁路货运制动盘冠的数值优化和实验验证。经分析的制动盘用于铁路货车，每轴的负载能力为22.5吨。每个车轴上都装有两个分开的铁路货运制动盘。借助数值分析，优化了制动盘的散热性能，减少了通风损失，并将数值结果与实验结果进行了比较。进行了单向流固耦合分析。用于预测空气流动特性和热对流的分割铁路货运制动盘的计算流体动力学模型已被纳入到盘的有限元模型中，并用于评估盘的温度。还对制动盘的冷却肋进行了数值参数优化，并开发了新颖的优化冷却肋。制动盘的瞬态热数值分析通过在测试台上进行制动测试期间获得的温度测量值进行了验证。在专门为此任务设计的测试台上测量了制动盘的通风损失，并将其与模拟结果进行了比较。实验获得的通风损失和温度测量值与模拟结果相比具有优势，证实了这种模拟过程可能会在未来可靠地应用。通过对分开的铁路货运制动盘进行系统优化，通风损失减少了37％，质量减少了21％，