Simulation of fully coupled thermomechanical analysis of disc brake rotor

Vehicle braking system is considered as one of the most fundamental safety-critical systems in modern vehicles as its main purpose is to stop or decelerate the vehicle. The frictional heat generated during braking application can cause numerous negative effects on the brake assembly such as brake fade, premature wear, thermal cracks and disc thickness variation (DTV). In the past, surface roughness and wear at the pad interface have rarely been considered in studies of thermal analysis of a disc brake assembly using finite element method.. The ventilated pad-disc brake assembly is built by a 3D model with a thermo-mechanical coupling boundary condition and multi-body model technique. The numerical simulation for the coupled transient thermal field and stress field is carried out by sequentially thermal-structural coupled method based on ANSYS to evaluate the stress fields and of deformations which are established in the disc had with the pressure of the pads and in the conditions of tightening of the disc thus the contact pressures distributions field in the pads which is another significant aspect in this research .The results obtained by the simulation are satisfactory compared with those of the specialized literature. Key –words:Brake Discs, Pads, Heat flux, Heat transfer coefficient, Thermo-mechanical coupling, Von Mises stress, Contact pressure