To study the vibration characteristics and stress state of brake discs during vehicle operations, a spatial trailer car-track coupled dynamics model was developed with the consideration of flexible brake disc. In the model, the components of a trailer car are considered as rigid bodies. Flexible models of the brake disc and wheelset were established using the finite element method. The trailer car-track coupled dynamics model is validated using experimental test results. The effects of wheelset flexible deformation on the dynamic properties of brake discs were investigated with the excitations of track irregularity and wheel flats. Furthermore, the brake disc was systematically evaluated and discussed under the condition of wheel flats in the coupled dynamics system. The results indicate that compared to rigid wheelsets with wheel flats, flexible wheelsets can cause the brake disc to vibrate more severely with higher stress. The severe vibration and high stress state of the brake disc could cause it to crack in the region near the bolts. The established dynamics model can be further developed and employed to assess the dynamics of the brake systems of high-speed trains.
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