Comparative thermo-structural analysis of grey cast iron and carbon-silicon carbide brake discs for military applications

The brake mechanism is a critical safety component in vehicles, where rotor design and material properties significantly influence performance. This study investigates the thermo-structural behaviour of brake discs for the HZJ79-TJMRS military patrol vehicle using finite element analysis. Models were developed in SolidWorks and analysed in ANSYS to assess von Mises stress, elastic strain, total deformation, heat flux, and temperature distribution. Two materials — Grey Cast Iron and Carbon-Silicon Carbide (C/SiC) — were evaluated. The C/SiC brake disc showed a 31% reduction in stress, 47% lower deformation, and over 39% higher heat dissipation efficiency compared to Grey Cast Iron. These findings were validated through simulation and comparative analysis with previous work. The results suggest that C/SiC is a superior candidate for high-performance brake systems in demanding military environments, contributing to enhanced safety, durability, and thermal management.