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ABSTRACT
In this paper, numerical simulation of transient thermal and static structural analysis was performed here sequentially with coupled thermo-structural method. Numerical procedure of calculation was based on important steps such as the Computational Fluid Dynamics (CFD) and thermal analysis which were well illustrated in 3D. Two different rotor designs and three different brake disc materials were tested and comparative analysis of the results was here conducted in order to get the one with the best thermal behaviour. The current numerical results were in good agreement with the previous experimental results available in the literature. Finally, the resolution of the thermo-mechanical coupling model allows us to visualise other important results of this research. According to the results presented in this study, several conclusions can be drawn. The choice will allow us to deliver the excellent rotor design to ensure and guarantee the good braking performance of the vehicles.
Nomenclature
| a | = | Vehicle deceleration (m/s2) |
| Ac | = | Surface area of the braking pad (m2) |
| Ad | = | Disc surface swept by a brake pad (m2) |
| Cp | = | Specific heat (J/kg°C) |
| E | = | Young modulus (MPa) |
| Fdisc | = | Rotor force (N) |
| g | = | Gravitational acceleration 9.81 (m/s2) |
| h | = | Heat transfer coefficient (W/m2°C) |
| k | = | Thermal conductivity (W/m°C) |
| m | = | Vehicle mass (kg) |
| P | = | Pressure for a single pad (MPa) |
| q0 | = | Heat flux entering the disc (W) |
| Rrotor | = | Effective rotor radius (m) |
| Rtire | = | Tire radius (m) |
| tstop | = | Time to stop (s) |
| v | = | Velocity vector (m/s) |
| v0 | = | Initial speed of the vehicle (m/s) |
| z | = | Braking effectiveness (z =a/g) |
Greek symbols
| α | = | Thermal expansion coefficient (1/°C) |
| εp | = | Factor load distribution on the disc surface |
| µ | = | Friction coefficient |
| ρ | = | Mass density (kg/m3) |
| υ | = | Poisson coefficient |
| ϕ | = | Rate distribution of the braking forces between the front and rear axle |
| ω | = | Angular velocity (rad/s) |
Subscripts
| CFD | = | Computational fluid dynamic |
| FG | = | Gray cast iron |
| HTC | = | Heat transfer coefficient |
Disclosure statement
The authors declare that there is no conflict of interest.
Additional information
Notes on contributors
Ali Belhocine
Dr Ali Belhocine received his Ph.D. degrees in Mechanical Engineering at the University of Science and the Technology of Oran (USTO Oran), Algeria. His research interests include Automotive Braking Systems, Finite Element Method (FEM), ANSYS simulation, CFD Analysis, Heat Transfer, Thermal-Structural Analysis, Tribology and Contact Mechanic.
Asif Afzal
Dr. Asif Afzal is assistant professor at Department of Mechanical Engineering, P. A. College of Engineering, Mangalore, India, His research interests include Computational Fluid Dynamicscomputational Heat Transferenergyexperimental Heat Transfernanofluids.