THERMAL ANALYSIS OF DISC BRAKE

INTRODUCTION:

• Friction based braking system is a common device to convert kinetic energy into thermal energy through a

friction between the brake pads and the rotor faces.

• Brake absorbs the kinetic energy of the rotating part and the energy is dissipated in the form of heat to the

surroundings.

• The main purpose of this study is to analysis the thermomechanical behavior of the dry contact of the brake

disc during the braking phase. The coupled thermal analysis is used to determine the deformation and the

disc for both solid and ventilated disc with three different materials to enhance performance of the rotor

disc.

Governing equation

Software packages

1. Solid works[modelling]2. Ansys[thermal-analysis]

MODELING

Ventilated disc brakes

Solid disc brake

Flow chart :

MESHING

Nodes-128713Elements-84162

Nodes-1415428Elements-826374

MATERIAL PROPERTIES

Aluminum

SteelGrey cast iron

ANALYZING[Solid body]

[ventilated body]

ALUMINUM

GREY CAST IRON STRUCTURAL STEEL

TOTAL HEAT FLUX DEFORMATION FOR A SOLID BODY

ALUMINUM

GREY CAST IRON STRUCTURAL STEEL

TOTAL HEAT FLUX DEFORMATION FOR A VENTILATED BODY

COMPARISON

Material Max temp°f

Min temp°f

Grey cast iron 148.71 94.56

Aluminum 135.77 109.22

Steel 146.34 96.75

Material Max temp°f

Min temp°f

Grey cast iron 140.67 85.59

Aluminum 131.07 100.54

Steel 139.14 87.60

Ventilated modelSolid model

CONCLUSION• The main conclusions drawn from the program of work reported in this paper are as

follows.

• In this study, we presented results of the thermal behavior of full solid and ventilated discs in a steady state. we study the thermal behavior of a gray cast iron. In addition, the influence of disc ventilation on the thermal behavior of the discs brake was analyzed. The numerical simulation shows that radial ventilation plays a very significant role in cooling of the disc during the braking phase.

• Thermal analysis is carried out for the application of braking force because of friction for the time duration of 1 seconds.

• The maximum temperature obtained in grey cast iron rotor disc is at rubbing surface & is observed to be 148.71˚f.

• The grey cast iron rotor disc is safe based on strength & stability criteria.

• To achieve a best combination of parameters of rotor disc like size, type & materials, & thermal analysis for 3 different material combinations were done.