Thermal Stress Analysis Of Disc Brake Rotor By Finite Element Method

Disc brakes are exposed to large temperature resulting large thermal stress during routinernbraking. These large temperature extrusions have two possible outcomes: fade that generatesrnreduction in stopping power; and large amount of plastic deformation that generates low fatiguernlife in the brake rotor. The aim of the present work is to investigate the temperature and thermalrnstress response of gray cast iron disc brake during first braking phase using analytical, as well asrnfinite element (FE) method and comparing the result. The area of study is concentrated onrntemperature variation as a function of thickness only. Only the areas exposed to high temperaturernis selected for analysis, specifically the rotor, by excluding hub and vanes because they are forrnfrom disc-pad contact. One particular existing brake disc design for a SUV car of modelrnDD6470C is chosen for the investigation. The dimensions, material property and maximumrnallowable speed of this car are used as an input both for analytical and finite element method.rnAnalytically the distribution of temperature caused by applied heat flux as a function of discrnthickness is solved by the method of partial solutions. The finite element simulation for therncoupled transient thermal field and stress field is carried out by separate data base thermalstructuralrncoupled method based on ANSYS 14.0 to evaluate the stress fields and temperature.rnDue to circumferential and axial symmetry of the disc, only half thickness of the disc is usedrnaxially, and 15.65° is used circumferentially in finite element analysis by ANSYS. The resultsrnshow maximum temperature and compressive stress components at the surface and these affectsrntribological properties such as damage and failure at the surface of the disc. In addition, it wasrnfound that high thermal load leads to brake fade and low fatigue life time of cast iron due tornsurface rupture of the rotor. Good agreement was obtained between FEM and analytical analysisrnbraking cycles to failure.rnKey words: Analytical analysis, Heat flux, Finite element method, Stress components,

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