The brake system is a critical component for vehicles as its main function is to inhibit motion by converting the kinetic energy of the vehicle into heat by friction. Heat energy generated by this conversion process must be dissipated away to the surroundings to protect the brake system from overheating. Ensuring the correct functioning of brake system under various load scenarios is a safety issue. Experimental testing of the brake system under various scenarios is challenging and time consuming. Computational Fluid Dynamics (CFD) simulations can be used to predict the brake system component temperatures and allow detailed investigation of heat flux distribution for various operating conditions and material properties with a shorter turnaround time. Building a reliable, repeatable, and an efficient scalable CFD process for brake cooling applications can be a challenge. This paper summarizes a CFD methodology using a co-simulation approach for brake cooling for two specific scenarios. An alpine descent where the vehicle is constantly braking during downhill travel and a repeated drive cycle where the vehicle is accelerating and decelerating. In the co-simulation approach, steady state fluid and transient solid rigid body rotation simulations are solved separately within the same simulation file and the two-way coupling of the two simulations are done over several cycles to allow the transfer of heat energy between fluid and solid simulations. Steady state fluid simulation solves for the convective and radiative heat transfer and transient solid rigid body rotation solves for the conduction by modelling the rotational effects of the brake. In comparison to the test data, the brake cooling simulation methodology using the co-simulation approach accurately predicts temperature trends at brake disc probe locations. The streamlined process developed here can help engineers to easily setup the CFD model to perform design exploration and optimization studies of the brake systems to accurately predict temperature distribution on critical components and visualize the heated airflow around the brake system.
Reference | NWC23-0151-presentation |
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Authors | Kulkarni. H Veeraraghavan. K |
Language | English |
Type | Presentation |
Date | 18th May 2023 |
Organisation | Siemens Digital Industries Software |
Region | Global |
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