Optimizing Ventilated Disk Brake Design for Enhanced Thermal Performance: An Analytical and Experimental Approach

Abstract

The primary purpose of the present investigation is to contribute to the invention of a methodology for determining the innermost temperatures in disc brakes at any range from its mid plane employing the Fourier transformation and Laplace transforms. These methods were utilized to investigate the interior surface temperature throughout braking under pad stress and disc tension circumstances. The initial segment of the mathematical simulation of the innermost temperature within the brake disk showed that the disk surface were the most relevant factor among the parameters under investigation. In the next segment experimentation approach, the ambient temperature along the interface among the pads and disk fluctuate between 97.8°C to 306.7°C because the rotation speed fluctuates across 300 rpm to 1100 rpm and the load from 20 N to 80 N. Another benefit section studies the flow of air, convection heat exchange parameters, and speeds, with validations using CFD simulation. The interface ranges (36.45°C to 91.668°C) were estimated with CFD. The vented brake rotors component was created as a three-dimensional model in modeling software and then loaded analysis software for estimating the disc's entire heat transfer including total thermal surface flux. It is possible to examine brake disks with complex geometries and concepts, especially tapered rotor disks, three-hole disks, among four-hole disks. The tapered rotor four-hole design has the greatest heat flux (489.32 W/m°K) and the greatest heat transfer factor (171262.8 W/m²) relative to other designs, and reaches the lowest temperatures (101.2°C). Mathematical, CFD, and testing examination of the suggested tapered rotor four-hole disk brake design revealed optimal thermal dissipation.