Thermal—mechanical coupled simulation of a solid brake disc in repeated braking cycles

Abstract

Braking operation is a process that converts kinetic energy and potential energy of a moving automobile into other energies. Most of the mechanical energy is transferred into heat. Frictional heat, which is generated on the interface of the disc and pads, can cause high temperature during the braking process. The objective of the present work is to determine temperature distribution, thermal distortion, and thermal stress in a solid disc by three-dimensional modelling for repeated braking. Braking is applied four times in the present study; the vehicle is decelerated from 100 to 50 kph with 0.6 g, after which the velocity is again accelerated to 100 kph. In order to simulate the friction heat behaviour accurately in repeated braking, the moving heat source, which is defined by time and space variable, is applied on the frictional surface. The temperature field and thermal stress in the disc present a non-uniformity characteristic because of the moving heat source. Temperature and thermal stress of the point on the frictional surface of the brake disc present fluctuation in the braking operation. The coning angle due to the non-uniform radial temperature distribution varies with temperature. Thermal fatigue is also discussed in this article.