A CASE STUDY ON THERMAL ANALYSIS OF THE DISC BRAKE USED FOR HEAVY-DUTY CARS

Abstract

The brake system converts kinetic energy into thermal energy, resulting in a rise in the temperatures of the disc brake due to the friction caused by the pressure brake between the turntable and the brake pads. This study aimed to investigate the thermal analysis of the disc brake used for heavy-duty cars. The study focuses on designing the ventilated brake disc for a particular Mitsubishi Pajero car through modeling software and observing the performances of two materials such as grey cast iron and cast carbon steel. Holes were also included on the surface of the rotor to speed up heat dissipation during and after braking. By utilising SimulationXpress and ANSYS Workbench, stress and thermal behaviour were analysed to choose a material that would perform better and reduce the damage brought on by high temperatures. It was observed that cast carbon steel with 30 vanes showed better performance for stress analysis. The transient thermal analysis for solid and drill disc brakes using cast carbon steel showed that the disc brake with holes performs better, even reducing vanes from 36 to 30. The study proves that a drilled disc with 30 vanes and made of cast carbon steel is the better choice for performance and heat dissipation.