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Flow and Heat Transfer Analysis of Variable Diameter Circular Pillar Disc Brake
Rotor Using CFD
Abstract—In the present work, ventilated disc brake rotors improved heat dissipation capability of a brake rotor can
with variable diameter circular pillar configurations were reduce the amount of thermal storage required by rotor;
analyzed to enhance the heat dissipation and obtain more which will allow for smaller and lighter rotors and can
uniform temperature distribution in the rotor. CFD code used reduce the vehicle weight and help to improve fuel economy.
in this work was validated with experimental results obtained Ventilated disc brake rotors having internal air flow
by conducting experiments on a test rig. Experimental analysis passages are widely used in an attempt to increase the level
was performed on existing taper radial vane (TRV) rotor to of forced convection and to improve the heat dissipation.
calculate the mass flow rate and heat transfer coefficient. Many rotor geometry configurations were analyzed to
Further, variable diameter circular pillar (VDCP) rotor with
improve the heat dissipation capability of the rotor. There are
different configurations namely VDCP1, VDCP2 and VDCP3
several considerations in the design of a ventilated disk brake
were considered for the analysis. A 20° segment of rotor was
considered for the numerical analysis due to its rotational rotor. The rotor allows an air to flow through it but it is
symmetry. CFD results were in good agreement with the equally complicated to achieve the balance between flow of
experimental analysis. The maximum deviation of numerical air and convective heat dissipation.
results were about 15% from the experimental results. It is The attempt of this work is to enhance the heat
found from the analysis that among all the rotor configurations; dissipation from a ventilated disks brake rotor by using
VDCP1 rotor configuration gives better rate of heat dissipation different rotor geometry configurations. The mass flow
and more uniform temperature distribution in the rotor. through the ventilated disc brake rotor and its heat transfer
Hence for modern high speed vehicles VDCP1 rotor coefficient has estimated by CFD computation. A novel
configuration may be more appropriate. design of the rotor geometry configuration has proposed to
improve the heat dissipation capability of a rotor. Most of the
Keywords-ventilated disc brake rotor; CFD; heat dissipation; previous researchers have measured the air flow velocity
flow passage and mass flow rate profile using particle image velocimetry (PIV). In some
cases they have used hot wire anemometry to examine the
I. INTRODUCTION flow field at exit of rotor.
The earlier work by Limpert (1975) was mainly
Automotive brakes are utilized to convert the kinetic
dependent on the experimental approach to determine the
energy of a moving vehicle into thermal energy through the
heat dissipation characteristics of the rotor. Thomas and
friction between stationary brake pads and a rotating surface.
Kwangjin (2000) have suggested the analytical method to
This is commonly done by using a cast iron rotating brake
determine the heat input and cooling characteristics of a
rotor with stationary friction surfaces mounted on a device
brake system with resultant distortion and stress components
called the brake calliper. Rotors may be solid or it may have
within the brake rotor. In his earlier paper (Kwangjin, 1999)
two disks separated by an air flow passage for ventilation. In
has carried out the analysis for computer modelling
high demand braking applications, vented disks are normally
techniques to predict the brake fluid temperature rise and
employed because they utilize a greater surface area to
other brake component temperatures during braking.
dissipate the heat. The brake rotor must be capable to store a
McPhee and Johnson (2008) have employed an analytical
significant amount of thermal energy while bringing a
and experimental approach to understand the convection
vehicle to stop; as braking occurs in a relatively short period
through flow passages of a rotor. The velocity field was
of time. The brake rotor must then dissipate the stored
determined by using PIV and flow patterns were observed
thermal energy quickly to the surrounding fluid in order to be
for presence of recirculation zones on the suction side.
ready for the next application of the braking. This heat is
Reddy, Mallikarjuna and Ganesan (2008) have performed
dissipated by convection from the surfaces of the rotor. If
this heat is not dissipated from brakes it will result in numerical simulation and compared the results with
warping, cracking, hot judder, brake fading, brake fluid experimental data. CFD analysis was performed on different
vaporisation and overheating of seals and other components. types of rotor configurations to investigate the heat transfer
The ventilated disks act like an air pump, circulating air from from passage surfaces and its symmetry. CFD simulations of
centre through the passages to the outside of the rotor. The the flow passages have proven to capture the main features
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The conventional type of disc brake rotor is a taper radial The flow is assumed to be steady and incompressible.
vane (TRV) rotor which has shown in Figure 2(a). Variable Atmospheric pressure and temperature are assumed as zero
diameter circular pillar rotor shown in Figure 2(b) has gauge and 300K. Walls of the rotor are assumed at constant
mainly developed to get an advantage of curved flow temperature of 350K, 375K and 400K for a speed of 500 and
passages and bi-directionality i.e. it can be applied on both 700 rpm separately. Buoyancy and radiation effects are
sides of vehicle. In the present study disc brake rotors are neglected in this analysis. The convective heat transfer can
analyzed for 500 and 700 rpm speed, which are be considered in two parts. The first involves convection
approximately 60 and 80 km/hr for a particular utility vehicle. from all external surfaces and second involves convection
Figure 3 shows the 20° sections of different rotor geometry through the flow passages. The latter aspect has concentrated
configurations considered for analysis. here for the analysis.
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The grid independence study was carried out for these TABLE I. EXPERIMENTAL RESULTS
results with grid sizes of 300000, 350000, 382000, 397000, Sr Speed Initial Final Time Mass Heat h
425000 and 450000 elements for TRV rotor. The variation in No (rpm) Disc Disc (sec) flow Loss (W/m2K)
number of elements for TRV rotor shows unchanged results Temp Temp rate (watt)
at approximately 400000 elements as shown in Figure 4. (°C) (°C) (g/s)
1 525 92.4 66.4 300 6.8 407.6 62.50
2 524 85.0 60.8 300 6.8 379.4 65.59
3 530 60.8 50.6 300 6.8 159.9 47.44
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made here to maintain more uniform temperature distribution Table V gives the mass flow rate at various speeds for
on the rotor surfaces by obtaining more uniform heat different VDCP rotor configurations. Highest mass flow rate
dissipation from the rotor surfaces. of air is found in VDCP3 rotor at all speeds and temperature
conditions i.e. 61% higher than VDCP1 and 4% higher than
VDCP2at 500 rpm speed and 350K temperature. The
difference in mass flow rate of VDCP2 and VDCP3 rotor is
not significant. Among all the rotor configurations, lowest air
movement is found in VDCP1 rotor. The small diameter
pillars of VDCP1 configuration increases the area of flow
passage but reduces the pressure drop across the rotor and
ultimately mass flow through the rotor.
The relative merits of rotor flow passage configurations
cannot be described by mass flow rates alone. It is important
to achieve an improvement in heat transfer coefficient and
uniformity in temperature distribution by more uniform heat
dissipation from the rotor surfaces. In an ideal condition; no
Figure 8. Variation of heat flux with temperature @ 500 rpm. temperature gradient is expected across the rotor.
Table IV shows the similar trend described by different
rotor configurations for heat flux. Highest heat flux is found
TABLE V. COMPARISON OF MASS FLOW RATE (G/S) THROUGH for VDCP1 rotor i.e. 20% higher than VDCP2 and 16%
ROTOR PASSAGES
more than VDCP3.
Mass Flow Rate Mass Flow Rate Mass Flow Rate Figure 7 and 8 shows the trend of heat transfer coefficient
Type of Rotor
(g/s) 300K (g/s) 375K (g/s) 400K and heat flux for different rotor configurations with respect
500 700 500 700 500 700 to temperature.
rpm rpm rpm rpm rpm rpm The isothermal surface temperatures of rotors were
VDCP1 0.51 0.50 0.34 0.32 0.34 0.32 specified as 350K, 375K and 400K for the speed of 500 and
VDCP2
700 rpm separately.
1.26 1.99 1.26 2.033 1.26 1.83
VDCP3 1.32 2.07 1.38 2.22 1.38 2.22
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(c) VDCP3 (c) VDCP3
Figure 9. Velocity vectors for VDCP rotors @ 500 rpm.
Figure 10. Streamlines for VDCP rotors @ 500rpm.
Figure 9 and 10 shows the velocity vectors and
stremlines at mid plane of the passages of different rotors at
500 rpm and 350K. The highest heat transfer coefficient The flow passage of VDCP1 rotor is wider than VDCP2
obtained for VDCP1 rotor is due to the increased area of and VDCP3 rotor. The increased surface area of VDCP1
flow passage and reduced separation of flow in the rotor. The rotor results in improved heat dissipation and better
next highest heat transfer coefficient is for VDCP2 rotor and temperature distribution in the rotor. It is found that the
lowest heat transfer coefficient is obtained for VDCP3 rotor. velocity distribution is more uniform for the configuration of
Though the mass flow through the VDCP1 rotor is small VDCP1 as compared with VDCP2 and VDCP3.
compared with VDCP3 rotor; but it shows that, the available
mass flow has utilized in the better way for heat dissipation.
The poor heat dissipation characteristic of VDCP2 and VDCP3
rotor is because of formation of recirculation zones and separation
of flow behind the pillars.
(a) VDCP1
(a) VDCP1
(b) VDCP2
(b) VDCP2
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APPENDIX
(c) VDCP3
Figure 11. Temperature counters for VDCP rotors @ 500rpm.
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