Numerical Optimization and Experimental Validation of Divided Rail Freight Brake Disc Crown

In this article the numerical optimization and experimental validations of a divided rail freight brake disc crown made from grey cast iron EN-GJL-250 are presented. The analysed brake disc is used for rail freight wagons with a load capacity of 22.5 ton per axle. Two of divided rail freight brake discs are mounted per axle. With the help of numerical analysis the thermal dissipation properties of the brake disc were optimized and ventilation losses were reduced. Numerical analysis were validated with measurements. New, patented type of cooling ribs of the disc causes lower temperatures during braking periods. An optimised brake disc has 37 % less ventilation losses and 21 % less mass while obtaining better thermal performance.