This content is not included in your SAE MOBILUS subscription, or you are not logged in.
Brake Duty Cycle Simulation for Thermal Design of Vehicle Braking System
ISSN: 0148-7191, e-ISSN: 2688-3627
Published May 15, 2013 by SAE International in United States
Annotation ability available
Successive braking of the vehicle, hereinafter referred as brake duty cycle, can elevate the temperature of the brake disc to a very high level. Such high temperatures reached in brake discs can lead to vaporization of the brake fluid if the vehicle is at rest after the brake duty cycle. Excessive temperature operation of the brake disc can also lead to thermal cracks, judder, brake fade, wear and reduce braking effectiveness. Simulation tools can be used to predict the excessive temperature reached during successive braking event. After visualizing the complex flow field over the brake system and analyzing the heat transfer from brake system, simulations can be employed at the early design stage to optimize the design for more airflow over brake discs thus reducing the high temperatures and associated brake fade.
In this paper, a CFD model of the vehicle with brake system is coupled with a thermal solver at braking and acceleration velocities. Heat input due to conversion of Kinetic Energy of the vehicle is calculated from the velocity fluctuations during braking and acceleration events. Calculated heat input along with heat transfer coefficients (HTC) variation due to speed changes are used in a standalone thermal simulation to predict the temperature of entire brake system including brake disc after each braking event in a ten brake stop brake duty cycle. Use of solid mesh for brake disc and neighboring parts such as hub and rim, further enhances the temperature prediction by modeling the conduction during heat up and cooldown event precisely. Multiple design iterations can be executed in a rapid turn-around time to analyze and improve the brake cooling performance.
|Development of a High Fidelity CAE Model for Predicting Brake System Temperatures
|CFD and CAE Approach for Brake Rotor Thermal Analysis
|High-Fidelity Transient Thermal Modeling of a Brake Corner
CitationBhambare, K., Haffey, M., and Jelic, S., "Brake Duty Cycle Simulation for Thermal Design of Vehicle Braking System," SAE Technical Paper 2013-36-0015, 2013, https://doi.org/10.4271/2013-36-0015.
- Jelić , S. , Meyland , S. , Jansen , W. , Alajbegovic , A. 2010 A Coupled Approach to Brake Duty Cycle Simulation 8th MIRA International Vehicle Aerodynamics Conference
- Lee , K. 1999 Numerical Prediction of Brake Fluid Temperature Rise during Braking and Heat Soaking SAE transactions 108.6 PART 1 897 905
- Stephens A. 2006 Aerodynamic Cooling of Automotive Disc Brakes MS Thesis RMIT University
- Emery , A. , F. , Kumar , P. , Firey , J. , C. 1997 Experimental Study of Automotive Brake System Temperatures Washington State Transportation Center
- Michelin Truck Tire Service Manual 2004 Michelin Tire Company
- PowerFLOW User's Guide, 4.3c 2010 Exa Corporation Boston, Massachusetts
- Bhatnagar , P. L. , Gross , E. P. and Krook , M. 1954 A Model for Collision Processes in Gases. I. Small Amplitude processes in Charged and Neutral One-component System Phys. Rev. 94 511 525
- PowerTHERM Users Guide, PowerTHERM 10.0 2010 Thermo Analytics, Inc. 23440 Airpark Blvd, Calumet, MI 49913
- Schütz , T. , Wiedemann , J. , Wickern , G. , Mukutmoni , D. , Wang Z. , and Alajbegovic , A. 2008 A Coupled Approach to Brake Cooling Simulation 7 th MIRA International Vehicle Aerodynamics Conference
- Wiesche S. 2007 Heat Transfer from a Rotating Disk in a Parallel Air Crossflow International Journal of Thermal Sciences 46 745 754
- Mukutmoni , D. , Jelic , S. , Han , J. , and Haffey , M. Role of Accurate Numerical Simulation of Brake Cooldown in Brake Design Process SAE Int. J. Passeng. Cars - Mech. Syst. 5 4 1199 1210 2012 10.4271/2012-01-1811