Statistical and mathematical modeling of temperature dynamics in automotive brake components: A systematic review

K. AGRAWAL, Vikash · 2025 · Crossref

DOI: 10.14744/sigma.2025.00128

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Summary

This systematic review addresses the critical need for accurate thermal modeling in automotive disc brake systems to enhance vehicle safety and performance. The study is motivated by the increasing complexity of braking mechanisms, particularly with the advent of electrified vehicles, which requires a deeper understanding of heat dissipation dynamics. The primary research objective is to evaluate and synthesize statistical and mathematical methodologies for predicting temperature fluctuations in brake liners and discs during deceleration. The authors emphasize that controlling heat transfer is essential for preventing brake fade, managing thermal stresses, and optimizing the design of rotor brakes under varying speed and load conditions. The review analyzes a wide range of computational and experimental techniques used in existing literature. Key methods include Computational Fluid Dynamics (CFD) for modeling fluid flow, temperature distribution, and thermal conductivity, as well as Finite Element Modeling (FEM) for transient thermal-structural analysis. The authors also examine mathematical algorithms utilizing Laplace and Fourier transforms to solve time-dependent heat conduction problems and Navier-Stokes equations for fluid dynamics. The synthesis covers various operational parameters, including vehicle speed, pedal effort, coefficient of friction, and deceleration rates. The review compares solid versus ventilated disc designs, noting that ventilated discs generally offer better cooling but may introduce judder issues due to uneven temperature distributions. Specific tools mentioned include ANSYS Multi-physics, ABAQUS, and MATLAB, which are used to simulate heat flux, convection, radiation, and conduction processes. The findings highlight that rotor velocity significantly impacts thermal performance, with higher speeds increasing the volumetric flow rate and heat transfer efficiency through rotor passages. The review notes that while convection is the primary heat dissipation mechanism under typical conditions, radiation becomes significant at high temperatures. Specific simulation results cited in the literature indicate optimal temperature variations for vented rotors ranging from 345.44°C to 401.5°C, with peak temperatures reaching up to 543.9°C in rigorous testing, remaining below the critical threshold for grey cast iron (~550°C). The study also identifies that friction coefficients diminish as disc temperatures approach 300°C, affecting braking efficiency. Furthermore, the integration of CFD with statistical simulations provides a robust framework for validating theoretical models against empirical data, ensuring accurate predictions of thermal behavior. The significance of this work lies in its comprehensive evaluation of thermal management strategies, providing a foundation for designing more efficient and reliable brake systems. By synthesizing diverse modeling approaches, the review offers insights into optimizing brake geometry, material selection, and ventilation designs to mitigate thermal degradation and wear. The authors conclude that advanced computational modeling is crucial for addressing the thermodynamic challenges of modern braking systems, ultimately contributing to improved vehicle safety, reduced maintenance needs, and sustainable automotive engineering practices. This systematic examination paves the way for future innovations in brake design by clarifying the precision and applicability of current predictive methodologies.

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Topics

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• braking response