Drum brakes are a key safety component in heavy commercial vehicles, so they need accurate failure characteristic models. Drum cracking is the most common failure mechanism for drum brakes. This paper presents a coupled temperature-stress model for drum brakes that can obtain the dynamic stress curves for accelerated fatigue working conditions. Then, this paper fitted the relationship between the stress and strain of the material on the inner drum surface at high temperatures and used the former dynamic stress curves as the fatigue load. The Manson-Coffin-Basquin model was then used to predict the failure life of each point on the inner surface. This drum brake lifetime prediction method was then verified against accelerated fatigue test results. This model can include the effects of the load fluctuations on the drum during use, as well as the effect of the material performance degradation at high temperatures. This model is useful for optimizing engineering designs of drum brakes.
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