Effect of Aspect Ratio on Asymmetrical Wear of Brake Pads Under High-Speed and Heavy-Load Braking Conditions

This study investigates the influence and mechanisms of friction blocks with varying aspect ratios on the asymmetrical wear of brake pads under high-speed and heavy-load braking conditions. A large megawatt-level wind turbine brake device was used, and the Archard wear model was integrated into the analysis of brake interface wear characteristics through the finite element method (FEM) and arbitrary Lagrangian-Eulerian (ALE) technology. A thermal-mechanical-wear coupling model was developed for brake systems with five different aspect ratio friction blocks, and its accuracy was validated through wear tests on an inertial brake test bench. A method for calculating tangential and radial wear is proposed to characterize the degree of asymmetrical wear at the friction interface. The study revealed a nonuniform wear distribution at the contact interface, with greater wear observed at the leading and outer edges of the friction block. A small aspect ratio (L/W < 1.5) predominantly results in radial wear, while a large aspect ratio (L/W > 1.5) leads to tangential wear. An aspect ratio of 2:1 balances radial and tangential wear, indicating improved wear resistance.