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The lateral runout of disc brake corner components can lead to the generation of brake system pulsation. Emphasis on reducing component flatness and lateral runout tolerances are a typical response to address this phenomenon. This paper presents the results of an analytical study that examined the effect that the attachment of the wheel to the brake corner assembly could have on the lateral distortion of the rotor. An analysis procedure was developed to utilize the finite element method and simulate the mechanics of the assembly process. Calculated rotor distortions were compared to laboratory measurements. A statistical approach was utilized, in conjunction with the finite element method, to study a number of wheel and brake corner parameters and identify the characteristics of a robust design.

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.