Thermomechanical Analysis of the Curve–Zigzag, Straight, and Straight–Pillar Vane Ventilated Disc Brake Rotors for Light Vehicles

Automotive braking systems are crucial components of cars because they help slow down and stabilize the vehicle when it is stopped. The majority of a vehicle’s kinetic energy is transformed into thermal energy during braking because of the effects of dry friction. This study analyzes the thermomechanical behavior of the straight vane, curve–zigzag, and straight–pillar vane ventilated disc brake rotors. The main objective of the study is to analyze the thermomechanical behavior of the disc brake rotor analytically and numerically. The coupled field transient and static structure analysis Ansys 2022 R1 Workbench served as the foundation for this analysis. The results have been used to compare that the rotor having a straight vane made of gray cast iron on its surface exhibited 148.5°C of temperature, 1.39 W/mm 2 total heat flux, 0.262 mm deformation, and 105.7 MPa of equivalent (Von Mises) stress. For carbon steel material, the curve–zigzag vane ventilated disc brake rotor is 0.2378 mm, 229 Pa, 138.7°C, 1.1 W/mm 2 , and 5 × 10 7 , respectively; the straight–pillar vane ventilated disc brake rotor is 0.235 mm, 179.5 Pa, 137°C, 1.38 W/mm 2 , and 5 × 10 7 , respectively; and the straight vane is 0.27 mm, 217 Pa, 141°C, 1.39 W/mm 2 , and 5 × 10 7 , respectively. The straight–pillar and curve–zigzag vanes have shown much lower thermal and structural behavior than the existing straight profiles. The straight–pillar vane ventilated brake disc model is the one suggested for a more cost‐effective and secure operation.