Numerical Analysis of Structural and Thermal Characteristics of Automotive Disc Brake Rotor

Brake discs are components that are subjected to both structural and thermal deformations simultaneously. The pressure exerted by the brake pad on the disc leads to strains, whilst the heat generated due to friction results in thermal stresses. The problems dealing with the numerical analysis and the strength prediction of the brake disc are generally a complex problem that involves coupled structural and thermal analysis. The application of composite materials in the brake rotor improves the braking torque to weight ratio, but the system fails due to overheating. Whilst designing a brake rotor, it is important to develop the model with enough strength, lesser inertia and better thermal conductivity and heat dissipation properties. The heat dissipation can be increased by providing more area for conduction or increased airflow for enough forced convection. But the increase in holes may sometimes lead to increased stress concentration or reduced strength for the brake discs. Hence the design of brake rotor generally involves a proper selection of material for enough strength, an optimum number of holes for proper convection and lower deformations due to the combined action of pressure and temperature. The current work involves developing a numerical model of brake disc, static structural and dynamic/transient analysis, combined structural and thermal analysis. The literature dealing with the numerical analysis of brake discs with the coupled structural and thermal conditions is very rare. The numerical model is validated with the help of experimental modal analysis.