Experimental and numerical study of turbulent flow and thermal behavior of automotive brake disc under repetitive braking

Abstract

The frictional brake system is the most safety critical equipment to decelerate or stop a vehicle. Thermal performance of the frictional region parts, disc and pads, necessitates to evaluate precisely in the design and test steps. In this study, a brake test setup was designed and fabricated with exactly the same braking components used in a common passenger vehicle as disc, pads, rim, tire, and dust shield to simulate the sequential braking. The local temperature on the disc and pads and the brake fluid pressure were measured. In addition, a three dimensional numerical model was designed to simulate the aerodynamics and thermal performance of the braking in detail. Finite element method was employed to simulate the frictional heat between the brake disc and the pads. The results showed that although the velocity of mainstream airflow reduces significantly into the rim, turbulent flow develops in the form of eddies of swirling airflow. Additionally, transient temperature distribution on the braking components was predicted. The cooling vanes in the brake disc have considerably enhanced the convection heat transfer. The amount of convective heat transfer on the inner radial vanes was more than 58% of the total amount of convective heat transfer.

Research progress of temperature field calculation of disc brake braking interface based on numerical analysis

“…The structure of the ventilated brake disc is constructed by constructing a series of radial vanes or pin-fins between two parallel friction surfaces, which not only increases the contact area with the air, but also allows the cold air around to be drawn into the channels of the disc to take away the heat, 81 so the optimization of the geometry of the ventilated brake disc is of great design significance to improve the heat dissipation capability of the brake. For example, Jafari and Akyüz 82 conducted a numerical study on the geometric parameters of radial vane disc brakes, and found that the ventilation gap has the greatest impact on the heat dissipation performance of the brake disc.…”

“…The current research methods mainly include brake interface temperature test, 25 analytical calculation, 26–31 and numerical analysis. 32–92 Among them, the experimental exploration method is effective but costly, the analytical calculation of temperature field is accurate but difficult to solve, and the numerical analysis uses numerical methods to find the approximate solution, which is not very accurate, but with the continuous development of computers, the...…”

“…Therefore, numerical analysis has become an important and indispensable method for studying the temperature field of the disc brake interface. There are many numerical analysis methods, such as finite difference method, 32–40 finite element method, 41–88 boundary element method, 89 and so on. Among them, the finite element method is the most commonly used, but in specific applications, the established thermal numerical model, the numerical calculation method used, the loading boundary conditions, and the various forms, each method has its own unique characteristics.…”

Heat dissipation optimization of ventilated brake disc recirculation zone based on NSGA-II algorithm

“…In the literature, 10 many methods have been used to study the flow field and heat transfer characteristics in the brake disc passage.…”