Feasibility of CFD-thermal-structural simulation based on real braking tests

2026-36-0331

7/30/2026

Authors
Abstract
Content
During the development of mechanical components, engineers use numerical tools as a first step to design, develop, and analyze potential solutions for specific requirements, thereby reducing time- to-market of new components. Furthermore, numerical tools are also highly useful for analyzing components that exhibit failures. For brake discs, numerical analysis must consider not only mechanical behavior but also thermal and fluid dynamic behavior. In this context, as a further step, experimental tests can be performed in test facilities such as dynamometers, where the brake discs are evaluated under different operating conditions to determine their susceptibility to failures such as thermal distortion, judder (hot or cold), squeal, coning, etc. If such failures occur, corrective actions can be implemented using different approaches: a) redesign of the disc and braking system aided by numerical tools; b) tuning of the matching between disc and pad materials; and c) modification of the disc and/or the pad material. Regarding the first approach, the finite element method (FEM) is one of the most important numerical tools, and to obtain reliable results, accurate boundary conditions must be applied. The aim of the study is to demonstrate the feasibility of the CFD-thermal-structural boundary conditions derived from an experimental test performed on a ventilated brake disc assembled in an instrumented vehicle. Firstly, a comparison between an analytical method and the CFD solution was made regarding convective heat transfer coefficient (HTC). The test consisted of 16 main braking cycles from 140 to 0 km/h, conducted under eight different pedal pressure levels. After each main braking, a thermal shock was applied to the disc using water, followed by a secondary braking from 80 to 0 km/h, always with the same pedal pressure. The numerical analysis results showed good agreement with experimental tests in terms of temperature distribution. In addition, axial displacement distribution along the circumference is presented, with emphasis on coning deformation, one of the main triggers for judder.
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DOI
https://doi.org/10.4271/2026-36-0331
Citation
Bagatini, P., Viotti, M., Pereira, L., Tuzzin, M., et al., "Feasibility of CFD-thermal-structural simulation based on real braking tests," 17th SAE BRASIL International Colloquium on Brakes and Engineering Exhibition., Farroupilha, Brazil, May 13, 2026, https://doi.org/10.4271/2026-36-0331.
Additional Details
Publisher
Published
12 hours ago
Product Code
2026-36-0331
Content Type
Technical Paper
Language
English