Computation Design and Analysis of Brake Disc with Various Profiles

In automobiles, the most commonly used braking system is disk brake. The disk is the important component in either slowing or stopping the vehicle. When a brake is applied, there occurs friction between the brake pad and the disk. Due to this action, a large amount of heat is generated. In order to reduce the generated heat, different sandwich structures were designed. The main objective is to analyze the thermal behavior of the sandwich ventilated structures of different profiles and compare their results and suggest the suitable ventilation structure that highly influences the convective heat transfer of the brake disc under on-road rigorous braking conditions. The chosen brake disc material is titanium alloy. The profiles which are analyzed are X-core, Corrugated, Round O-core and Honeycomb. The heat transfer and the pressure drop characteristics of the sandwich structures were found with one face sheet heated by constant heat flux and cooled by forced air convection. The results show that overall heat transfer rate is a function of surface area density, cell shape and the thermal conductivity of the solid material. The best suitable profiles with respect to static structural and thermal conditions were identified.