Finite Element Modelling of Ventilated Brake Disc Hot Spotting

Hot spotting of automotive disc brakes is an undesired thermal localisation phenomenon, which is a challenge for numerical modelling in terms of both accuracy and efficiency especially for complex disc geometry. In this research, the aim was to develop a computationally efficient finite element (FE) approach for 2-piece pin-mounted ventilated disc hot spot prediction with acceptable accuracy enabling parametric studies to contribute to the knowledge of the complex mechanisms. A time reduction strategy for the simulations was established by incorporating an axisymmetric brake pad assumption with material scaling factor and the friction characteristics were defined by a user-subroutine. The computing accuracy and efficiency of this method were then verified by comparing with traditional FE models. 2D in-plane, 2D out-of-plane, and 3D models were performed to investigate the effects of ventilated disc hot spotting, radial hot spot/band migration, and hot spotting of realistic complex disc geometry respectively. Both 2D and 3D results were validated using experimental results based on a laboratory dynamometer and showed good correlation. The results suggested that adequate modelling of friction pair contact pressure distribution and the subsequent non-uniform heat generation is essential for hot spot simulation; speed was identified as the determinant for the number of hot spots, whereas hot spot temperature was determined by energy level. Furthermore, recommendations for vent design, pins, disc run-out, cooling, material selection, wear rate, pad length and loading distribution were given. Finally, hot spotting and hot band migration cause-effect chains were established based on the results and discussion.Appendix 1 and Appendix 2 are unavailable online due to copyright restrictions