2006-01-3203

Fundamental Study
on Thermal Behavior of Brake Discs

Toshikazu OKAMURA
Hiroyuki YUMOTO
KIRIU CORPORATION
 Contents
1. Introduction
p Necessity for studying disc thermal behavior to reduce coning
p
p Trends in basic configurations of brake discs
p

2. Experimental results for disc thermal behavior with various discs

3. Study of sensitivity of dimensions on coning for outer-hat discs

4. Concluding remarks

2006-01-3203 －3
 Three Sources of Brake Torque Vibration

Mechanical Source
BTV
Thermal Source
Chemical Source

Mechanical associated with kinematic behavior of brake disc

Source and caliper from DTV
Thermal high-temperature environment could distort brake
Source discs through combination of coning and warpage
Chemical associated with chemical process or lining transfer
Source that results in variations in friction characteristics
Breakdown by A. C. Leslie in SAE 2004-01-2777
2006-01-3203 －4
 Effect of Thermal Deformation on Judder
Non-uniform Local
disc material On wear Off-brake On-brake

Off
DTV Hydraulic
(growth) vibration
LRO LRO
(growth)

On
Thermal
deformation BTV Judder

Machining Uneven
accuracy On heating
Uneven
On Friction
Uneven film
DTV formation

Corrosion
2006-01-3203 －5
 Classification of Disc Basic Configurations

Outer hat Outer hat Inner hat Inner-hat

Type Floating
w/o neck w/neck w/o hole w/hole

Schematic
Drawing

2006-01-3203 －6
 Trends in Configurations of Front Brake Discs
100% Floating
90%
Percentage of Disc Configuration

80%
Inner hat
70%
60% Deep neck (w/ and w/o holes)
50%
40%
30%
20% Shallow neck Outer hat w/neck
(deep and shallow)
10%
0%
Korea

Italy
US

UK

France
Germany
Japan

Sweden

Outer hat w/o neck

Country
250 cast-iron discs exhibited at Tokyo Motor Show
2006-01-3203 －7
 Contents
1. Introduction

2. Experimental results for disc thermal behavior with various discs

p Difference in the amount of thermal coning between discs types
p Correlation between CAE and physical tests

3. Study of sensitivity of dimensions on coning for outer-hat discs

4. Concluding remarks

2006-01-3203 －8
Displacement Sensor Setting on Brake Dyno

2006-01-3203 －9
 Difference in Coning between Disc Types
600

500
+
400
Amount of Coning (μm)

300

200

100

-100

-200
0 100 200 300 400 500
Temperature on Brake Effective Radius (℃)

2006-01-3203 －11
 Correlation between Physical Test and CAE
700

600 CAE Test

Outer
Thermal Displacement (μm)

500 Inner 40
400

300

200

100

0
0 100 200 300 400 500
Temperature at Brake Effective Radius (℃)

2006-01-3203 －12
 Accurate Simulation with Conventional CAE
Correlation and feedback
CAE

700

600

Thermal Displacement (μm)

500

400

300

200

100

0
0 100 200 300 400 500
Temperature at Brake Effective Radius (℃)

Physical test

2006-01-3203 －13
 Contents
1. Introduction

2. Experimental results for disc thermal behavior with various discs

3. Study of sensitivity of dimensions on coning for outer-hat discs

p Design of experiment for CAE parametric study
p Results of CAE parametric study
p Discussion on CAE experimental results
p Design strategy for thermally stable disc

4. Concluding remarks

2006-01-3203 －14
Background of DOE for CAE Parametric Study
p Floating discs have very little thermal coning.
p Inner-hat discs also have advantages in thermal coning
compared to outer-hat discs.
p However, floating or inner-hat discs sometimes reveal
deficiencies in terms of manufacturing costs and operational
reliability compared to outer-hat discs.
400

300
Amount of Coning (μm

Floating
200

100

Inner hat
-100
0 100 200 300 400
Temperature on BER (℃)
2006-01-3203 －15
 Objective of DOE for CAE Parametric Study

Ultimate feasibility to
reduce thermal coning

CAE Parametric Study

using Taguchi Method

Outer-hat disc with neck

p Determine the critical parameters to reduce the amount of coning

p Establish a design strategy to obtain thermally stable brake discs
with an outer-hat configuration

2006-01-3203 －16
 Steps for CAE Parametric Study

1 DOE assigned in L36 orthogonal array

2 Creation of mesh model with our design system

3 Thermal analysis using FEA

4 Collection of data from the simulated results

5 Calculation of S/N ratio & Sensitivity

6 Discussion on the results

2006-01-3203 －17
Factor and Level Assigned in L36 (211x312)
Factors Levels Range (mm)
Disc outer diameter Fixed 360
A Pad inner diameter 2 220 240
B Outboard neck outer diameter 2 157 231
C Neck wall thickness 1 2 6 12
D Neck wall thickness 2 2 6 13
E Neck corner radius 2 0 8
F Outboard plate necking depth 2 0 3
G Hat wall thickness 2 5 7
H Hub contact area allowance 2 0 16
I Fixing-plate-to-hat corner R 2 1 4
J Hub contact surface corner R 2 0 16
K Vane inner diameter 2 148 240
L Outboard plate inner diameter 3 161 240
M Inboard plate inner diameter 3 144 236
N Disc thickness 3 28 40
O Outboard plate thickness 3 8 13
P Neck height from inboard 3 0 32
Q Outboard inner corner radius 3 2 12
R Effective offset 3 20 60
S Road wheel contact diameter 3 138 214
T Hat inner diameter 3 144 200
U Hub contact area diameter 3 140 198
V Extended vane inner diameter 3 144 240
W Vane number 3 36 54
2006-01-3203 －19
 Factorial Levels for CAE Parametric Study
p Some factors based on the practical standard dimensions
¾ Outer diameter and disc thickness based on BM database
45 95% Upper Bound
Predicted Value
40 95% Lower Bound
Disc Thickness (mm)

35

30

25

20

15

10
200 220 240 260 280 300 320 340 360 380 400 420
Outer Diameter (mm)

p Other factors calculated using the sliding-factor-level technique

2006-01-3203 －21
 Disc Models for CAE Experiment

#01 #02 #03 #04 #05 #06

#31 #32 #33 #34 #35 #36

2006-01-3203 －22
 Contents
1. Introduction

2. Experimental results for disc thermal behavior with various discs

3. Study of sensitivity of dimensions on coning for outer-hat discs

p Design of experiment for CAE parametric study
p Results of CAE parametric study
p Discussion on CAE experimental results
p Design strategy for thermally stable disc

4. Concluding remarks

2006-01-3203 －23
Typical Results for Thermal Analysis
#19

#14

2006-01-3203 －24
 Simulated Axial Thermal Displacement
400
700
300
217 μm
Amount of Coning (μm

600
200

500
100

Displacement (μm)
400
0

-100 300
0 100 200 300 400
Temperature on BER (℃)
200

100

0 -44 μm

-100
130 140 150 160 170 180
Radius (mm)
2006-01-3203 －25
 Calculation of S/N Ratio and Sensitivity
p Taguchi’s S/N ratio for “0-is-Best”
1
S / N ratio = −10 log Ve ym =
n
∑ yi

Sensitivity = ym S T = ∑ yi
2

S m = (∑ yi )
700
1 2
600

500
n
S e = ST − S m
Displacement (μm)

400

300

1
200
Ve = Se
100
+ n −1
0
where
-100
130 140 150 160 170
-
180
Ve : error variance
Radius (mm)
ym : mean of response
yi : response
Noise factor: radial position 2006-01-3203 －26
 Sensitivity for Thermal Deflection (μm) S/N Ratio for Thermal Deflection (db)

-39
-38
-37
-36
-35
-34
-33
-32
-31
-30
-29

20
40
60
80
100
120
140
160
180
200
220
A1 Pad inner

A
A2 diameter A1
A2
L1 Outboard plate L1

L
L2
L3 inner diameter L2
L3
M1 Inboard plate M1

M
M2
M3 inner diameter M2
M3
N1
N1

N
N2 Disc thickness
N3 N2
N3
O1 Outboard plate O1

O
O2 O2
O3 thickness
O3

Axial movement
P1 Neck height P1
P2 P P2
P3 from inboard
P3
S/N ratio for coning

B1 Outboard neck
B1
B

B2 outer diameter B2
C1 Neck wall
C1
C

C2 thickness 1 C2
D1 Neck wall
D1
D

D2 thickness 2 D2
E1 Neck corner E1
E

E2 radius E2
Q1 Outboard
Q1
Q

Q2 inner corner Q2
Q3 Q3
radius
F1 Outboard plate F1
F

F2 necking depth F2
Less coning

R1 R1
R2
R

Effective offset R2
R3 R3
S1 Road wheel S1
S2
S

S2
S3 diameter S3
T1 Hat inner T1
T

T2 T2
T3 diameter T3
G1 Hat wall G1
G

G2 thickness G2
Less axially outboard movement

U1 Hub contact U1
U2
U

U2
U3 area diameter U3
H1 Hub contact H1
H

H2 area H2
I1 Fixing-plate- I1
I

I2 to-hat corner R I2
J1 Hub surface J1
J

J2 corner R J2
K1 Vane inner K1
K

K2 diameter K2
V1 Extended vane V1
V2 V2
V

V3 inner diameter V3
W1 W1
S/N Ratio & Sensitivity for Thermal Deflection

W2 Vane number W2
W

W3 W3
2006-01-3203 －29
 Sensitivi ty for Necking Stress (MPa) Sensitivity for Fixing Plate Stress (MPa)

140
150
160
170
180
190
200
210
220
230
240
250
100
120
140
160
180
200
220
240
260
280
300

A1 Pad inner A1

A
A2 diameter A2
L1 Outboard L1

L
L2 plate inner L2
L3 diameter L3
M1 Inboard plate M1

M
M2 M2
M3 inner diameter M3
N1 N1

N
N2 Disc thickness N2
N3 N3
O1 Outboard O1

O
O2 O2
O3 plate thickness O3
P1 Neck height P1
P2 P P2
P3 from inboard P3
B1 Outboard neck B1
B

Necking corner stress

B2 outer diameter B2
C1 Neck wall C1
C

C2 thickness 1 C2
Fixing plate corner stress

D1 Neck wall D1
D

D2 thickness 2 D2
E1 Neck corner E1
E

E2 radius E2
Q1 Outboard Q1
Q

Q2 inner corner Q2
Q3 Q3
radius
F1 Outboard F1
F

F2 plate necking F2
Less stress

Less stress
R1 R1
R2 R2
R

Effective offset
R3 R3
S1 Road wheel S1
S2 S2
S

S3 diameter S3
T1 Hat inner T1
T

T2 T2
T3 diameter T3
G1 Hat wall G1
G

G2 thickness G2
U1 Hub contact U1
U2 U2
U

U3 area diameter U3
H1 Hub contact H1
H

H2 area H2
Sensitivity for Thermal Stress

I1 Fixing-plate- I1
I

I2 to-hat corner R I2
J1 Hub surface J1
J

J2 corner R J2
K1 Vane inner K1
K

K2 diameter K2
V1 Extended V1
V2 V2
V

vane inner
V3 V3
diameter
W1 W1
W2 Vane number W2
W

W3 W3
2006-01-3203 －31
 S e n s itiv ity fo r T h e r m a l D e fle c tio n (μ m ) S /N R a tio fo r T h e r m a l D e fle c tio n (d b )

-39
-38
-37
-36
-35
-34
-33
-32
-31
-30
-29

20
40
60
80
100
120
140
160
180
200
220
A
P a d in n e r
AA 12 d ia m e te r

L
AA 12
O u tb o a r d p la te
LL 12 in n e r d ia m e te r LL 21
L3

M
In b o a r d p la te L3
MM 12 in n e r d ia m e te r MM 12
M 3

N
D is c th ic k n e s s M 3
NN 12 NN 12
N3

O
O u tb o a r d p la te N3
OO 12 th ic k n e s s
Coning

OO 12
O3

P
N e c k h e ig h t O3
PP 12 fr o m in b o a r d PP 12
P3 O u tb o a r d n e c k P3
BB 12 o u te r d ia m e te r
N e c k w a ll BB 12
CC 12 th ic k n e s s 1
N e c k w a ll CC 12
th ic k n e s s 2

B C D E
DD 12
N e c k c o rn e r DD 12
ra d iu s

Q
EE 12 O u tb o a r d EE 12
in n e r c o rn e r
QQ 12 ra d iu s QQ 12

F
Q3

Axial movement
O u tb o a r d p la te Q3
n e c k in g d e p th

R
FF 12 FF 12
RR 12 E ffe c tiv e o ffs e t RR 12
S
R3 Road w heel R3
SS 12 d ia m e te r T SS 12
S3 H a t in n e r S3
TT 12 d ia m e te r TT 12
G

T3 H a t w a ll T3
th ic k n e s s
U

GG 12 GG 12
H u b c o n ta c t
UU 12 a r e a d ia m e te r UU 12
H

U3 H u b c o n ta c t U3
a re a
I

HH 12 F ix in g -p la te - HH 12
to -h a t c o r n e r R
J

II 21 H u b s u r fa c e II 12
c o rn e r R
K

JJ 12 V a n e in n e r JJ 12
d ia m e te r
V

KK 12 KK 12
E x te n d e d v a n e
VV 12 in n e r d ia m e te r VV 12
W

V3 V3
WW 12 V ane num ber WW 12
W 3 W 3

S e n s itiv ity fo r N e c k in g S tr e s s (M P a ) S e n s itiv ity fo r F ix in g P la te S tr e s s (M P a )

140
150
160
170
180
190
200
210
220
230
240
250
100
120
140
160
180
200
220
240
260
280
300

P a d in n e r
AA 12 d ia m e te r AA 12
L

O u tb o a r d
LL 12 p la te in n e r LL 12
L3 d ia m e te r L3
M

MM 12 In b o a r d p la te MM 12
M 3 in n e r d ia m e te r M 3
N

NN 12 D is c th ic k n e s s NN 12
N3 N3
O

OO 12 O u tb o a r d OO 12
O3 p la te th ic k n e s s O3
P

PP 12 N e c k h e ig h t PP 12
P3 fr o m in b o a r d P3
O u tb o a r d n e c k
BB 12 o u te r d ia m e te r BB 12
N e c k w a ll
CC 12 th ic k n e s s 1 CC 12
N e c k w a ll
DD 12 th ic k n e s s 2 DD 12
B C D E

N e c k c o rn e r
EE 12 ra d iu s EE 12
Q

O u tb o a r d
QQ 12 in n e r c o rn e r QQ 12
Q3 ra d iu s Q3
F

O u tb o a r d
FF 12 p la te n e c k in g FF 12
R

RR 12 E ffe c tiv e o ffs e t RR 12

R3 R3
S

Road w heel
SS 12 d ia m e te r SS 12
S3 S3
T

H a t in n e r
TT 12 d ia m e te r TT 12
T3 T3
G
Best Solution for Thermal Behavior

H a t w a ll
GG 12 th ic k n e s s GG 12
U

H u b c o n ta c t
UU 12 a r e a d ia m e te r UU 12
U3 U3
H

H u b c o n ta c t
a re a
I

HH 12 HH 12
F ix in g -p la te -
II 12 to -h a t c o r n e r R II 12
J

H u b s u r fa c e
JJ 12 c o rn e r R JJ 12
K

V a n e in n e r
KK 12 d ia m e te r KK 12
V

E x te n d e d
VV 12 v a n e in n e r VV 12
d ia m e te r
Fixing plate corner stress

V3 V3
W

Necking corner stress

V ane num ber

2006-01-3203 －32

WW 12 WW 12
W 3 W 3
 Contents
1. Introduction

2. Experimental results for disc thermal behavior with various discs

3. Study of sensitivity of dimensions on coning for outer-hat discs

p Design of experiment for CAE parametric study
p Results of CAE parametric study
p Discussion on CAE experimental results
p Design strategy for thermally stable disc

4. Concluding remarks

2006-01-3203 －33
 Effect of Offset between Hat and Friction Plate

Offset Radial thermal expansion

Axial thermal expansion

700
ΔL = LαΔT
600

500
Displacement (μm)

400

300
where
L : hat axial length
200
α: coefficient of linear expansion
ΔT: temperature difference
100

-100
130 140 150 160 170 180
Radius (mm)

2006-01-3203 －34
 Pie-Sliced Disc and Simplified Model

Radial thermal expansion causes tilting.

Offset

Simplified model
Pie-sliced disc
with same width

2006-01-3203 －35
 Simplified Model as Cantilever
Higher D ML2

Thermal Expansion
D
y=
temperature EI
θ ML
θ=
EI
M y
θ=
θ L
B y
A
Virtual gap
A B
L
where
y : deflection
Lower θ : deflection angle
M : bending moment
temperature
L : hat axial length
E : elastic modulus
I : geometrical moment of inertia 2006-01-3203 －37
 Effect of Difference in Corner Rigidity
Square- Square- Round-
Corner Type
square round round

Drawing h
r

Geometrical
moment of
2 2bh 3
{
b 2h + ( )}
2 −1 r
　
3
bh 3
inertia 12 12 12
Rigidity Medium Largest Smallest
Fixing-plate-to-hat
corner
where
Hat-to-friction-plate
corner b : beam width
2006-01-3203 －39
Effect of Stiffness of Friction Plate
M
w∝
D
Eh 3
D=
(
12 1 −ν 2 )

where
w : deflection
D : disc flexural rigidity
for solid disc
h : disc thickness
ν : Poisson's ratio
2006-01-3203 －41
 Contents
1. Introduction

2. Experimental results for disc thermal behavior with various discs

3. Study of sensitivity of dimensions on coning for outer-hat discs

p Design of experiment for CAE parametric study
p Results of CAE parametric study
p Discussion on CAE experimental results
p Design strategy for thermally stable disc

4. Concluding remarks

2006-01-3203 －42
 Constraint in Vehicle
System Vehicle
Brake system
Requirements Brake disc
Performance
Brake effectiveness
Comfortableness
Vehicle NVH
Brake noise
Squeal
Judder
Durability
Packaging
Others
2006-01-3203 －43
 Design Strategy for Thermally Stable Disc
p Larger offset and thicker friction plates are recommended
if the OEM requirements permit us to do so
for a new vehicle at the earliest development stages.
p We can successfully design thermally stable brake discs
by applying the following strategies
under the dimensional constraints
to satisfy vehicle packaging requirements.
¾ Set the hat wall at the middle
of the hub and wheel contact areas of fixing plate and
the inner diameter of the pad rubbing surface
to achieve reduced stiffness around the hat
¾ Reduce the bending stiffness around the hat
with deeper necking
by having thinner walls under allowable stress
¾ Increase bending stiffness of friction plates
by smaller inner diameters for inboard friction plates
and internally extended vanes

2006-01-3203 －45
 Contents
1. Introduction

2. Experimental results for thermal behavior with various discs

3. Study of sensitivity of dimensions on coning for outer-hat discs

4. Concluding remarks

2006-01-3203 －46
 Concluding Remarks
p Reducing thermal coning in brake discs is significant.

p Conventional CAE methodologies have been applied

to designing new brake discs
obtaining good correlation between CAE simulation and physical tests.

p The most important factors

influencing outer-hat brake discs
during thermal deformation and the resulting stress
were clarified based on a CAE parametric study.

p To design new brake discs

satisfying the various requirements of individual vehicles
based on the acquired knowledge.

2006-01-3203 －48
 2006-01-3203

Fundamental Study
on Thermal Behavior of Brake Discs

Thank you.
Questions?

Toshikazu OKAMURA
E-mail t-okamura@kiriu.co.jp
URL http://www.kiriu.co.jp/
http://www.kiriu-usa.com/