Transient thermal analyses of an integrated brake rotor and wheel hub for heavy duty vehicles

Abstract

In this study, transient thermal analyses for a new integrated rotor and wheel hub concept are performed by consideration of convection, conduction and radiation effects. Test methods used for the characterization and certification purposes are constructed in a simulation environment and the effect of different ventilation vanes and rotor-hub arrangements on heat transfer mechanism is examined and the details are summarized for a reliable simulation process. Validated procedures are used to report a series of characterization and certification analyses, namely; CFD analyses including wheel assembly, cooldown analyses, R13 repeated stop fade and alpine hot descent analyses for current design and new integrated rotor and hub pair for alternative ventilation vane designs. The analyses are especially focused on predicting the cooling period and predicting maximum bearing temperatures for normal and excessive loading scenarios. To provide benchmark a commercial integrated rotor and hub pair used in heavy duty vehicles is also analysed. The average convective heat transfer coefficient and cooldown period of proposed integrated brake rotor are improved by 117.3% and 30.5% compared to the base design. The maximum wheel bearing temperature is decreased by 27.0% and by 27.1% for the proposed integrated brake rotor and wheel hub compared to the benchmark model, in accordance with the repeated stop and alpine hot descent analyses. In addition, the total weight reduction of 10 kg (15%) according to the base design is achieved.

A prediction method for convective heat transfer coefficients of brake discs based on small samples combined wind tunnel tests and CFD simulations

“…Güleryüz employed CFD for transient thermal analysis of a new integrated brake disc and wheel hub concept. In comparison to the baseline design, the proposed integrated brake disc exhibited a significantly higher average convective heat transfer coefficient [13].…”

“…Measurement of the local convective heat transfer coefficient of the sample is carried out according to equation (13). The physical quantities to be measured are t i , the temperature T i of the sample at time t i , and the far-field temperature T ∞ .…”

Design and Analysis of Active Cooled Brake Disc in Lattice Structure for Additive Manufacturing

“…Thilak ve arkadaşları [13], sert frenleme koşulları altında bir fren rotorunda geçici termal ve yapısal analiz yapmıştır ve disk rotor tasarımına yardımcı olmak için performansını değerlendirmiştir. Güleryüz ve Karadeniz [14], çeşitli havalandırma açıklıklı fren rotorları üzerine bir dizi hesaplamalı akışkanlar dinamiği (CFD) ve geçici termal analiz gerçekleştirmiştir. CFD analizleri, rotor-pabuç ve rotor-pabuç-tekerlek montajları için konvektif ısı transfer katsayılarını çıkarmak için yapılmıştır.…”

CFD and experimental study of heat dissipation from an anti-coning, pin vented, inboard mounted brake disc

“…As pointed out in Gu¨leryu¨z and Karadeniz, 13 most studies reported in the literature deal with brake rotors of passenger and high-performance cars, but only a few studies are related to heavy-duty vehicles. Previous work on heavy-duty vehicles was considered in Voller et al, 4 Galindo-Lopez and Tirovic, 14 Tang et al, 15 Stevens and Tirovic, 16 and Tirovic and Stevens 17 for instance, and only Tang et al 15 and Stevens and Tirovic 16 provided insights on the CFD aspects.The current study therefore aims at studying further the heat transfer of anti-coning brakes for heavy-duty vehicles, using CFD approaches.…”