Coupled thermal and structural analysis of disc brake rotor with varying angle of rotation of ventilation holes

Abstract

The automobile’s speed and torque requirements are growing all the time these days. As we all know, not only are speed and torque are a necessity of automotive manufacturers, but also braking without sliding and vehicle comfort is also a fundamental element. The major goal of this project is to study the impact of inclined holes on the disc brake rotor similar to that of Suzuki GSXR 1100 which will decrease overall deformation and maximize heat dissipation. AUTODESK FUSION 360 is used to create various forms of vented holes in a brake disc rotor. The inner and outer boundaries are retained, with changes occurring only in the intermediate patterns/regions between them, giving the models similar structural boundary limitations. ANSYS, a finite element software for calculating the temperature distribution, fluctuation of stresses and deformation throughout the disc brake profile, is utilized for the static structural analysis and steady-state thermal analysis of the brake disc rotor. To improve the quality of the results a coupled static structural and thermal analysis simulation was performed which showed a linear decline of temperature and total deformation with an increase in the angle of the holes. Thus, the effective lifetime of the disc brake rotor will be increased. Based upon the values of von-misses stresses, deformation, temperature, total heat flow obtained via ANSYS simulation, the best design changes in the brake disc rotor are proposed.