Numerical Investigation of Material and Structural Influence on Transient Temperature Behavior in Disc Brakes During Single-Stop Braking

While many techniques have been proposed to enhance heat dissipation in ventilated disc brakes during extended braking, solid disc brakes have received less attention, particularly under hard braking conditions. This study investigates the transient thermal responses of both solid and ventilated disc brakes during single-stop braking. Numerical simulations were conducted on three disc types: Solid, ventilated with 32 fins, and ventilated with 42 fins, each made from different materials: Grey cast iron, AISI 420, and INCONEL 718. The simulations assessed the maximum surface temperature and the temperature distribution across the disc thickness. The results indicate significant differences in thermal performance based on material properties and disc design. Grey cast iron exhibited the lowest maximum temperatures due to its high thermal conductivity, whereas INCONEL 718 showed the highest temperatures due to its lower thermal conductivity. Despite their improved cooling capabilities, ventilated discs demonstrated higher maximum surface temperatures compared to solid discs, due to their lower thermal capacity. These findings highlight the importance of material selection and structural design in optimizing brake disc performance under high thermal loads.