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Long repetitive braking, such as one which occurs during a mountain descent, will result in a brake fluid temperature rise and may cause brake fluid vaporization. This may be a concern particularly for passenger cars equipped with aluminum calipers and with a limited air flow to the wheel brake systems. This paper describes the computer modeling techniques to predict the brake fluid temperature rise as well as other brake component temperatures during braking and heat soaking. Numerical results are compared to the measured vehicle data and the effects of relevant brake system parameters on the fluid temperature are investigated. The techniques developed in this study will help brake engineers to build a safer brake system and reduce the extensive vehicle tests currently required.

The severe thermal distortion of a brake rotor can affect important brake system characteristics such as the system response and brake judder propensity. This paper will propose a technique to determine the thermal distortion under transient or steady state conditions. The technique involves utilizing a PC-based computer program to calculate the necessary thermal parameters and apply the results as input to a finite element-based thermal stress analysis. This unique approach provides a reliable methodology to determine the heat input and cooling characteristics of a given brake system in addition to resultant distortion and stress components within the brake rotor. Analysis results are also compared to measured temperature and distortion data.