Brake-disc transient thermal analysis

A structured investigation of how a ventilated brake disc absorbs and dissipates heat during a braking event, developed through analytical calculations, CAD and transient thermal simulation.

Engineering question

How does the disc's temperature field evolve during braking and subsequent cooling—and when is the numerical result sufficiently independent of mesh size?

The study is deliberately simulation-led. Its purpose is to demonstrate a traceable engineering workflow, not to claim physical test validation that has not been completed.

Model architecture

From vehicle energy to rotor temperature.

The loading chain connects the stopping event to the front axle, one brake disc and finally the two friction faces. Convection is applied to exposed surfaces to represent cooling to ambient air.

Vehicle kinetic energy→Brake energy split→Disc heat flux→Transient response

Study method

A defensible path from assumptions to results.

Define the braking event

Establish the vehicle, deceleration, rotor and stop conditions, then state every modelling assumption before simulation begins.

Calculate the thermal load

Translate kinetic energy, dynamic axle load transfer, brake distribution and rotor–pad heat partition into a time-dependent heat flux.

Build the engineering model

Create the ventilated brake-disc geometry in SolidWorks and prepare named faces for repeatable loading and result extraction in ANSYS.

Verify before interpreting

Use analytical temperature-rise checks and a licence-safe mesh-convergence study before drawing conclusions from temperature and heat-flux results.

Technical foundation

Inputs selected before the solver is trusted.

The model uses literature-supported thermal properties and boundary conditions, with calculations retained so that every applied value can be reviewed and reproduced.

CAD

Ventilated rotor

Parametric disc, hat, mounting features and 36-vane arrangement.

LOAD

Transient heat flux

Calculated braking energy applied across the two friction faces over the defined stop time.

COOL

50 W/m²·K at 20°C

Convection applied to the named exposed-surface selection to represent cooling to ambient air.

Current project status

The baseline transient model is established; verification is under way.

The braking event, analytical heat-load method, material-property basis, rotor geometry, convection condition and transient heat-flux loading have been developed. The baseline ANSYS model now includes the two loaded friction faces and the exposed-surface convection condition. The present stage is a licence-safe mesh-convergence study designed to identify a stable result within the available ANSYS limits.

Scope and assumptions

Complete

Load calculations

Complete

CAD and baseline model

Complete

Mesh convergence

In progress

Results and discussion

Next

Project integrity

Temperature findings will be published only after mesh convergence and analytical temperature-rise checks are documented.Return to Automotive