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This paper presents four different modeling approaches for the thermal analyses of disc brakes. The models, ranging from a simple lumped-parameter model to a complex three-dimensional model, have all been found to be useful depending on the need at hand. A lumped-parameter (zero-dimensional) rotor model predicts transient bulk rotor temperatures, while a one-dimensional model provides peak surface as well as bulk temperatures. A steady-state, two-dimensional model of the entire brake system predicts plateau temperatures during a multi-stop driving schedule. Finally, a complex three-dimensional transient model can be used to obtain detailed local rotor temperature distributions for any stoping sequence. Each modeling approach is presented here with experimental validation of the predicted results.

The mechanical behavior of a passenger car disc brake sliding caliper is analyzed in order to better understand the parameters that influence rotor/pad pressure distribution. The analysis uses proven techniques for solving free boundary contact problems. Complementarity equations for a gap between adjacent nodes are formulated in terms of the contact compliances for the inboard and outboard pad/rotor interfaces and for the piston/inboard-shoe interface. These equations also capture the influence of rigid-body motion of the various caliper components resulting from the translation and rotation needed to satisfy static equilibrium. The finite element method is employed to calculate the compliance matrices for all the contact interfaces. An iteration scheme is developed to solve the nonlinear system of complementarity equations for each of the three contact problems.