Experimental and numerical thermal analysis of formula student racing car disc brake design

Formula racing car brakes undergo massive loading not only mechanical, but thermal as well. There are various problems that occur due to brake assembly components reaching very high temperatures such as brake fade, induction of thermal stresses and chances of thermo-mechanical fatigue of components taking the braking loads. Hence analyzing the brake components for thermal loads becomes very important. This paper deals with the theory behind thermal analysis of the brake, the method used to calculate the conversion of the car's kinetic energy to the brake's heat energy, to find the convection coefficient available due to the air flow on the car and to determine the overall temperature rise on the brake disc. This paper shows simulations conducted in various software and the data as well as the graphs obtained from these simulations. Similar type of data and graphs are obtained from the actual testing with the use of various sensors mounted on the car. In the end there is a comparison made between the simulation and the data obtained from the car's testing to verify the method used for its accuracy and reliability.