This paper presents a two-way thermally-coupled FEM-CFD co-simulation method for ventilated brake disc rotor heat transfer analysis. Using a third party coupling interface for data mapping and exchange, the FEM and CFD models run simultaneously under a standard heavy duty braking test condition. By comparison with conventional one-way coupling methods and experimental results, the performance of the co-simulation system has been investigated in terms of prediction of the heat transfer coefficient (HTC) and disc temperatures as well as computing time used. The results illustrate that this co-simulation method has good capacity in providing cooling effect and temperature predictions. It also shows that the data exchange between the FEM and CFD codes at every time increment is highly accurate and efficient throughout 10 brake applications. It can be seen that the co-simulation method is more time efficient, convenient and robust compared to previous one-way coupling methods. To utilize the potential of this method, future works are proposed.

Jinghan, Tang; Hongsheng, Qi; University of Bradford