Analysis of the transient thermomechanical behaviour of a lightweight brake disc for a regenerative braking system

Abstract

Regenerative braking would extend the working range of an EV or HV provided that any extra energy consumption from increased vehicle mass and system losses did not outweigh the saving from energy recuperation, also reduce duty levels on the brakes themselves, giving advantages including extended brake rotor and friction material life, but more importantly reduced brake mass, minimise brake pad wear. The objective of this research is to define thermal performance on lightweight disc brake models. Thermal performance was a key factor which was studied using the 3D model in FEA simulations. Ultimately a design method for lightweight brakes suitable for use on any car-sized hybrid vehicle was used from previous analysis. The design requirement, including reducing the thickness, would affect the temperature distribution and increase stress at the critical area. Based on the relationship obtained between rotor weight, thickness, undercut effect and offset between hat and friction ring, criteria have been established for designing lightweight brake discs in a vehicle with regenerative braking.