This content is not included in your SAE MOBILUS subscription, or you are not logged in.
Simulation-Driven Process to Evaluate Vehicle Integration Aspects in Brake Thermal Design
ISSN: 0148-7191, e-ISSN: 2688-3627
Published May 24, 2017 by SAE International in United States
This content contains downloadable datasetsAnnotation ability available
Thermal performance of a brake system is one of the key attributes in a new vehicle development process. Adequate brake cooling characteristics are part of the vehicle performance and safety requirements.
The design of a new brake system, however, can be a complex task from a thermal engineering perspective, particularly because of complex interactions between the brake component and the rest of the vehicle. Frequently, the vehicle integration issues are the most serious challenges for brake engineers. There are considerations on how much heat should be dissipated from a single and/or consecutive braking events vs. how much cooling can be provided to the brake corner. Design issues such as where to direct the cooling air to how much flexibility is allowed while complying with other requirements from the studio and aero teams. For a brake engineer, the priority is to maximize cooling to the brake corner and prevent system failure.
Furthermore, material selection is another key design factor. The recent trend in the automotive industry to reduce vehicle weight includes the use of new lightweight materials for brake cooling components. The impact of different thermo-physical properties of these new materials needs to be analyzed to fully understand the thermal responses of the new brake system.
In this study, a full vehicle analysis on the thermal performance of a vehicle’s brake system was carried out to demonstrate the overall simulation process. The effects of all heat transfer modes including convection, radiation, and conduction were accounted for in the analysis. Particular attention to examine the effects of possible design choices such as convective cooling enhancement features and component material selection. Some of the design parameters greatly alter the thermal performance of the brake, while others are much less pronounced. The trade-off aspects with aerodynamic impact was examined as well. The “digital design process” described in this study can provide valuable physical insights to brake engineers when they look for reliable answers to “what if” questions for design iterations.
|Technical Paper||Analysis of Factors Affecting Rainwater Ingestion into Vehicles HVAC Systems|
|Technical Paper||A CFD Investigation of Aerodynamic Effects of Wheel Center Geometry on Brake Cooling|
CitationOcampo, J., Jelic, S., and Han, J., "Simulation-Driven Process to Evaluate Vehicle Integration Aspects in Brake Thermal Design," SAE Technical Paper 2017-36-0011, 2017, https://doi.org/10.4271/2017-36-0011.
Data Sets - Support Documents
|Unnamed Dataset 1|
- Jelić , S. , Meyland , S. , Jansen , W. , Alajbegovic , A. 2010 A Coupled Approach to Brake Duty Cycle Simulation 8th MIRA International Vehicle Aerodynamics Conference
- Bhambare , K. , Jelić , S. , Haffey , M. 2013 Brake Duty Cycle Simulation for Thermal Design of Vehicle Braking System SAE International 2013-36-0015
- Day , A. 2014 Braking of Road Vehicles Elsevier Publishing 255 256
- 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, WA-RD 434.1
- Limberg , J. Introduction to Foundation of Brake Design SAE, Brake Colloquium and Exhibition
- PowerFLOW User’s Guide, 5.3c 2016 Exa Corporation Boston, Massachusetts
- PowerTHERM Users Guide, PowerTHERM 12.1 2016 ThermoAnalytics, 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 7th 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