Thermal loading of brake discs is well understood at relatively low operating temperatures, and therefore modeling of disc thermal performance at low temperatures is also relatively well understood. However, at more critical temperatures, the thermal load can adversely affect the braking performance, leading to brake fade. This work utilizes advanced thermal modelling together with dedicated vehicle testing to establish boundary conditions at higher braking temperatures. The specific thermal performance of each brake is tested at elevated temperature. This thermal performance data is then used to refine the thermal simulation model. To validate the model, a 15 stop fade cycle test is run. The model takes into account the solid conduction calculation through the disc, convective flow field analysis and the brake system thermal performance characteristic as previously described. The results of this new simulation are compared with the vehicle test results.

O'Meachair, Deaglan; Elliot, Gary; - Bentley Motors; Jelić, Sacha; Fechner, Boris; Bhambare, Kamalesh; - Exa Corporation