Investigation into How Brake Disc Design Affects cooling

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Presented by Sean Lydon

Aims and Objectives• Research the braking system in a vehicle

• Investigate the various designs of brake discs

• Complete and analyse the results of one practical braking test

• Complete bench test on brake discs and compare to road results

• Analyse all data and state the most efficient

Why are brakes used?• To stop you crashing or to slow you down from high speeds

• Using frictional forces from contact between pad & disc

• One of most important controls in any vehicle

• Designed to stop you in shortest possible distance

Various brake disc designs• Standard Brake disc

• Grooved brake disc

• Cross drilled brake disc

• Over 70 configurations, Straight, directional, pillared are most common

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Practical road test

• Grooved & drilled road test

• 80 km/h emergency stop

• Tested to see what heat was generated

• Later compare results with bench test

Methodology• Built a brake Rig to keep a consistence pressure

• Disassemble brake hose from calliper

• Connect pressure gauge

• Use thermal imaging camera

Test Equipment

• Use brake rig to set pressure @ 50 psi

• Connect with copper pipe and tee piece

• Have thermal imaging camera set correctly

Bench Practical Test 1

• Standard brake disc

• Using thermal imaging camera

• Speeds of 20-80 km/h @ 50 psi

• Apply brake for 30 seconds

• Take heat readings and graph

Bench Practical Test 2

• Grooved brake disc

• Speeds of 20-80 km/h @ 50 psi

• Apply brake for 30 seconds

• Take heat readings and graph

Grooved brake disc

Bench Practical Test 3

• Grooved brake disc

• Speeds of 20-80 km/h @ 50 psi

• Apply brake for 30 seconds

• Take heat readings and graph

Conclusions

• Compare all 3 brake discs heat values

• Analyse all data and make a conclusion

• How would I approach this research again

Heat Dissipation Results

• Standard brake disc

• Grooved brake disc

• Cross drilled brake disc

Final Temp @ 80 km/h

Final Temp @ 80 km/h

Final Temp @ 80 km/h

Airflow in a braking system

• Why is airflow important

• What happens as you drive along the road

Importance of Airflow in a Braking system

• Bench vs road tests

• How has it has affected my results

Recommendations

• Complete testing on a close strip of road

• Perhaps an alternative design?

• Use thermal analysis software SolidWorks

• Try alternative testing methods/Build a Rig?

Thank youAny Questions

Investigation Into How Brake Disc

Design affects cooling

BySean Lydon

Mechanical Engineering 2016