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Thermal Performance of Monolithic and Coated Disc Brakes Using Abaqus and Matlab Software

The brake system is a critical item of safety equipment in a vehicle and provides the driver with adequate control over the speed of the vehicle and is classified as one of the most crucial parts in any vehicle. Rotor reliability and the thermal behaviour of various small scale disc brake rotors were investigated using a small scale brake dynamometer rig and a number of different numerical approaches. Abaqus and Matlab software were firstly used to construct a one dimensional (1D) thermal model to investigate the thermal performance of disc brakes. The 1D model was validated with literature and experimental results. An axisymmetric thermal model was then developed using Abaqus in order to investigate the temperature distribution through the brake rotor. The effect of a coating layer on a disc brake rotor was investigated using Abaqus implicit analyses which included an enhancement of the modelling of the coating layer and as assessment of the results accuracy. Matlab code was constructed to communicate with the Abaqus input file in order to perform a repetitive braking events and optimisation analysis. This code was developed in order to save time and to utilise the optimisation toolbox in Matlab. The numerical results showed good agreement with the experimental results obtained from the literature.