This paper describes the concept of a monoblock cast iron ventilated automotive brake disc with a fingered hub. Such a design offers possibilities in reducing disc mass, improving cooling, reducing thermal stresses and coning. Furthermore, a fingered hub offers potential for ‘tuning’ NVH characteristics. Mechanical loading is a limiting factor for such a design. Three point bending tests on cast iron samples were conducted and combined with FE analyses, indicating that such a disc can be a realistic design solution. Consequently, brake discs for a light passenger car were manufactured and mechanical torsional tests conducted. The tests employed an advanced optical strain sensor and further confirmed the conceptual feasibility of the design. The results are very encouraging with further work needed for full design optimisation.

Stergios Topouris, Marko Tirovic, Michele Vianello, Correia Ricardo Goncalves - Cranfield University