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A computational analysis of heat transfer in solid and vented disc brakes: CFD simulation and thermal performance assessment

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Abstract

This research presents a computational approach to estimate the heat transfer of solid and vented brake discs. Based on research data, it has been observed that when driving at slower speeds, a vented rotor’s effectiveness in cooling greatly decreases, with most of the cooling being generated by the additional surface area. The measurement of heat transfer in commercial vehicle disc brakes is determined using standard connections and road test results. The objective is to achieve an excellent degree of system dependability at a low cost. The automotive sector is placing growing importance on technology-driven safety features, highlighting their increasing significance. Braking is a method of converting motion energy into thermal power, which needs to be dissipated as heat. Overheating may result in brake system breakdown, which is dangerous. Temperature stability is achieved through the thermal dissipation through the brake disc. The current study employed a novel approach to calculate the brake disc's coefficient of heat transmission and heat flow through the disc. The occurrence of autonomous vehicles provides a lot of potential advantages, both on a personal and community basis, including improved security and energy efficiency, greater heat loss, and less traffic concerns, among other things. According to Jiguang and Fei (Open Mech Eng J 9:371–378, 2015) and More and Sivakumar (Int J Eng Res Appl 4(4):01–05, 2014), temperature rises about 10 percent of the calculated value. Inside a brake disc and padding, temperature measurement to variations was  ± 6% as that estimated by Newcomb (Proc Inst Mech Eng Automob Div 12:227–244, 1958. 10.1243/PIME_AUTO_1958_000_028_02). At the high temperature of 450–650 °K, road speed would have to be approximately 80, 90, and 100 km/h for the vehicle under study. Higher-powered cars that use giant discs would need a road speed of 150 km/h in a single brake application. This information was then used to optimize the disc's boundaries and groove configuration to achieve maximum heat dissipation. Consequently, a significant increase in heat dissipation was observed by simply modifying the vane design with straight and drilling grooves. The percentage of total energy that has been dissipated in the brake linings is 1/17.92, which means that about 5.57 percent of the heat produced is absorbed by the linings. A rotor using straight vanes and 36 grooves performed highest in this study, and the approach used to calculate the transmission of heat across various disc sections has helped us comprehend commercial vehicle brake dissipation of heat.

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Data availability

The data will be made available on kind request to corresponding author.

Abbreviations

CFD:

Computational fluid dynamics

ICEM:

Integrated computer engineering and manufacturing

HTC:

Heat transfer coefficient

RNG:

Renormalization group

FEM:

Finite element method

FEA:

Finite element analysis

C p :

Specific heat capacity

V :

Linear speed at any instant

A :

Surface area of a disc brake rotor

ε :

Turbulent dissipation rate or the turbulent kinetic energy dissipation rate

ф :

Angular displacement

h :

Heat transfer coefficient

D :

Measurement of the size of the disc

K a :

Surface roughness thermal conductivity

m :

Mass

P :

Pressure

Re:

Reynolds number of the rotor

α :

Thermal diffusivity

P FV :

Braking force

t :

Duration of the disc

v 0 :

Disc's beginning velocity

a :

Acceleration

Q :

Cooling power

z :

Rate of braking

g :

Standard momentum of gravitation

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Authors and Affiliations

  1. Department of Automation and Robotics, Dr. D. Y. Patil Institute of Technology, Pimpri, Pune, India

    Vikash K. Agrawal & Lalit N. Patil

  2. Department of Mechanical Engineering, SIES Graduate School of Technology, Navi Mumbai, India

    Kaustabh Vijay Chavan

  3. Department of Mechanical Engineering, Thakur College of Engineering and Technology, Mumbai, India

    U. D. Nimbalkar

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  1. Vikash K. Agrawal
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  2. Lalit N. Patil
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  3. Kaustabh Vijay Chavan
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  4. U. D. Nimbalkar
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Agrawal, V.K., Patil, L.N., Chavan, K.V. et al. A computational analysis of heat transfer in solid and vented disc brakes: CFD simulation and thermal performance assessment. Multiscale and Multidiscip. Model. Exp. and Des. (2024). https://doi.org/10.1007/s41939-024-00400-y

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