Brake Disk Heat Transfer CFD Simulation
The car’s brake system consists of discs, calipers, and pads.
This product includes a CFD simulation and training files using ANSYS Fluent software.
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Brake Disk Project Description
In the brake system, the pads push on both sides of the disc by a piston embedded in the caliper. Thereby reducing the rotation speed of the disc till stopping. In the braking process, the mechanical energy is converted to thermal energy by the friction caused by the contact between the pad surface and the disk surface. However, this increase in temperature on the pads and discs causes them damage with lower brake quality and an ultimately shorter life. In Brake Disk heat transfer CFD simulation, we study the thermal behavior of the disc after applying the frictional force of the pad contact.
In fact, due to the high rotational speed of the disc, the friction between the pad and the disc generates very high heat inside the pad and disc, which damages the pad over time, and disrupts the performance of the brake system. Therefore, in order to improve the performance of the pad, we should attempt to prevent an excessive temperature rise of the pad and disc by creating heat transfer with ambient air. In the present model, we simulate the heat transfer within the pad caused by contact with the surface of the disc. The disc material is steel and rotates at a specified rotational speed.
The Assumption for Brake Disk CFD Simulation
Simulation is STEADY. In fact, the rotational speed of the rotating disk is constant over time.
The solver is Pressure-Based.
We ignore the effect of gravity.
Brake Disk Geometry & Mesh
Design Modeler software designed the 3-D geometry. The present model includes a rotating disc in the center and a dedicated airflow space around the disc. We also design a segment as the brake pad on the disk surface. Meshing was done using ANSYS Meshing software. The mesh type is unstructured with 198594 cells.
CFD Simulation Steps
Here is a summary of the steps to define and solve the problem:
|(boundary conditions)(Brake Disk)|
|air inlet||velocity||10 m.s-1|
|outlet air||1 (100%)|
|(heat transfer)||pad wall||heat flux||UDF|
|brake wall||wall rotational speed||0 rad.s-1|
|bulk temperature||300 K|
|other walls||heat flux||0 (insulated)|
As a result of the contact between the brake pad surface and the disc plate, heat is transferred from the disc plate to the surface of the pad. Due to the fact that the geometry of the pad is not symmetric, the distribution of heat transfer at different points of its surface varies depending on the radius of the fractional pad. Hence, the UDF code defines the transition heat distribution profile on the pad surface.
Frame Motion (Brake Disk)
Since the disk is rotating in the center part of the model, the Frame Motion technique has been used to define the rotational speed of the disk. The rotational speed for this disk is 20 rad.s-1.
All files, including Geometry, Mesh, Case & Data, are available in Simulation File. By the way, Training File presents how to solve the problem and extract all desired results.
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