Simulation and optimization of train brake disc based on coupling characteristics of FEM and thermal flow density method.

This study proposes a numerical simulation method based on the coupling of the FEM and HFDM to analyze the temperature field and stress field distribution of high-speed train brake discs under extreme operating conditions. Through multiphysics coupling analysis, the research optimizes the ventilation structure design of brake discs, significantly improving their thermal stability and structural strength. The method combines FEM's geometric discretization capability with HFDM's heat conduction simulation advantages, incorporating temperature-dependent material parameters and anisotropic heat flux formulas to enhance simulation accuracy under high-temperature conditions. Simulation analysis of three ventilation structures (standard cylindrical holes, inclined holes, and hybrid holes) was conducted using the ANSYS platform. The results demonstrate that the optimized design significantly reduces peak temperatures and stresses, with the hybrid hole design achieving a 15.8% reduction in peak temperature and a 45.4% reduction in peak stress. The biomimetic "plant breathing stomata" structure further optimizes airflow organization and improves heat dissipation efficiency. Mesh independence analysis and experimental validation confirm the method's reliability, with simulation errors below 5%.