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Abstract
Brake rotors generate an opposing torque to a shaft, converting kinetic energy to heat thus necessitating heat transfer considerations. To better
understand convection through the fins of a brake rotor, experimental and analytical methods were employed. The experimental approach involved
two aspects, assessment of both heat transfer and fluid motion. A transient experiment was conducted to quantify the internal (fin) convection
and external (rotor surface) convection terms for three nominal speeds. For the given experiment, conduction and radiation were determined to be
negligible. Rotor rotational speeds of 342, 684, and 1025 [rpm] yielded fin convection heat transfer coefficients of 27.0, 52.7, 78.3 [W m−2 K−1 ],
respectively, indicating a linear relationship. At the slowest speed, the internal convection represented 45.5% of the total heat transfer, increasing to
55.4% at 1025 [rpm]. Analytical solutions were evaluated where possible for the convective terms and found to be comparable to the experimental
results. The flow aspect of the experiment involved the determination of the velocity field through the internal passages formed by the radial
fins. Utilizing PIV (particle image velocimetry), the phase-averaged velocity field was determined. A number of detrimental flow patterns were
observed, notably entrance effects and the presence of recirculation on the suction side of the fins.
© 2007 Elsevier Masson SAS. All rights reserved.
Keywords: Brake rotor; Transient experiment; Radial fin; PIV; Forced convective cooling
Nomenclature
effect of turbulence and other such flow parameters, it does not temperature and mean heat transfer coefficients, the convective
guarantee increased convection. terms are defined as follows [10]:
Improved numerical models have been implemented, includ-
ing the effects of heat transfer, as demonstrated by Phan et al. Ėconv.e = hconv.e Ae (T − T∞ ) (1)
[7], Jones et al. [8], and Shen et al. [9]. Numerical models, Ėconv.i = hconv.i Ai (T − T∞ ) (2)
however, are often subject to significant assumptions. Corre-
lations to the experimental data have often relied on the bulk For this experiment, characterization of the aforementioned
performance in terms of heat transfer coefficients, rather than convective heat transfer terms was desired. Thus, the aim was to
consideration of an accurate flow field and addressing specific minimize the remaining heat transfer mechanisms, conduction
phenomena. (accounting for contact resistance) and radiation [10]:
The purpose of this experiment will be to characterize the
individual heat transfer mechanisms through transient testing. Ėcond = Ucond Ahub (T − T∞ ) (3)
This experiment will also evaluate the fluid motion through the Ėrad = hrad Ae (T − T∞ ) (4)
radial passages of the brake rotor using PIV (particle image ve-
hrad ≡ σ (T + T∞ ) T 2 + T∞
2
(5)
locimetry). Using the results of the heat transfer and PIV exper-
iments, the potential for accurate numerical modeling becomes Conduction, which occurs through the mounting hub, was min-
possible. Such a model could then be expanded to consider the imized through the use of an asbestos disc between the two
interaction with other vehicle components, such as the wheel mating surfaces, thus insulating the brake rotor. In an effort to
hub, caliper and shroud, accurately predicting in-vehicle heat reduce the radiation contribution, experimental operating tem-
transfer performance. peratures were limited, as radiation is a function of T 4 . Evalu-
ation of these assumptions will be provided during the analysis
2. Heat transfer of the results. Neglecting conduction and radiation terms, the
total heat transfer can then be expressed in terms of convection
2.1. Physical mechanisms alone:
The evaluation of heat transfer requires consideration of Ėout = Ėconv.i + Ėconv.e (6)
the individual contributing mechanisms, which for a brake ro- To quantify the rate of heat transfer, it was desired to con-
tor involves conduction, convection, and radiation. In terms duct a transient experiment. Applying an energy control volume
of convective heat transfer, the mechanism can be considered analysis to the surface of the brake rotor, the rate of change of
in two parts. The first involves convection from all external internal (stored) energy is defined as:
surfaces. The second, and of particular interest, involves con-
vection through the radial passages. Assuming constant surface Ėst = −Ėout (7)
460 A.D. McPhee, D.A. Johnson / International Journal of Thermal Sciences 47 (2008) 458–467
2.2. Lumped capacitance model Utilizing the preceding result, the heat transfer coefficients can
readily be determined by conducting a transient experiment.
To further analysis and to quantify the energy storage term,
use of the lumped capacitance model was desired, in part due 2.3. Experiment
to its simplicity. The lumped capacitance model is based on the
assumption that the temperature of the solid is spatially uniform For the experiment, a generic 37-radial fin vented brake rotor
at all times during a transient process [10]. This simplification was utilized as illustrated in Fig. 1. The rotor was fabricated
eliminates any spatial terms from the energy storage expression, from cast iron with a mass of 7.36 [kg] and specific heat of 566
and can be expressed as [10]: [J kg−1 K−1 ] [10]. The external and internal convective areas
dT were determined to be 0.120 and 0.102 [m2 ], respectively.
Ėst = mc (8) For each of the experiments, the brake rotor was heated to
dt
a uniform temperature of 583 [K] over a period of 45 minutes.
To ensure the validity of this assumption, the following require-
A maximum temperature of 583 [K] was selected to minimize
ment for the Biot number needed to be satisfied [10]:
the radiation and conduction heat transfer mechanisms. Further-
hlc
Bi = 0.1 (9) more, heating over a long period ensured spatial uniformity for
k the temperature distribution. To facilitate heating of the brake
In Eq. (9), a conservative estimate was used for h based on ini- rotor, a 5.5 kW induction heater was utilized, ensuring a spa-
tial test results, while k was defined by the material properties. tially uniform temperature distribution. A custom induction coil
Two methods exist for the determination of characteristic length was fabricated to accommodate the rotor geometry. During the
lc . The first, and most common approach, is to calculate the heating process, the rotor was slowly rotated to ensure uniform
length as the ratio of volume to surface area. The second, and heating.
more conservative approach, is to choose lc to be the length Upon reaching the desired temperature, the heat source was
corresponding to the maximum spatial temperature difference. removed and the brake rotor accelerated to a constant speed.
For the given rotor geometry, this corresponds to the mid-plane A custom test bench was fabricated to facilitate the rotation
lying between the two pad surfaces, a distance of 0.012 [m]. of the brake rotor, simulating in vehicle operation. The rotor
The first and second method for determining the characteristic was driven by a 1 [hp] DC motor, with speed controlled by
lengths yielded Bi values of 0.004 and 0.010, respectively, vali- an open-loop variable resistance drive. The rotor was attached
dating the uniform spatial temperature distribution assumption. to the motor via a hub assembly, with any obstructing shrouds
Referring back to the control volume energy balance (7), and removed. The inlet of the rotor faced outward from the hub,
substituting for the energy storage term (8), the lumped capaci- preventing any potential obstructions. The resulting setup best
tance model yields the following solution [10]: simulated the performance of an unobstructed brake rotor open
T − T∞ hconv.i Ai + hconv.e Ae to the atmosphere. The temperature decay of the brake rotor
≡ θ = exp − t (10) was monitored until a temperature of 323 [K] was reached and
T0 − T∞ mc
A.D. McPhee, D.A. Johnson / International Journal of Thermal Sciences 47 (2008) 458–467 461
Fig. 3. Non-dimensionalized temperature vs time for blocked vented rotor at Fig. 5. Non-dimensionalized temperature vs time for open vented rotor at
342 [rpm] (log plot). 342 [rpm].
Fig. 6. Non-dimensionalized temperature vs time for open vented rotor at Fig. 8. Heat transfer coefficient versus rotor speed.
342 [rpm] (log plot).
speeds tested, internal convection increases linearly with speed.
Observation of the external convective term proved less con-
clusive. Extrapolation of a linear fit for zero rotation yielded a
heat transfer coefficient of 14 [W m−2 K−1 ]. While the zero ro-
tation heat transfer coefficient cannot be validated, a non-zero
value was to be expected. Given the operating temperature of
the brake rotor, the external convective term actually comprises
of forced and natural convection. Thus, at zero rotation, convec-
tive heat transfer would occur by means of natural convection.
However, since the natural convection was not quantified dur-
ing the experiment, nothing can be stated regarding the linearity
of the external convective heat transfer.
Comparing the two convective mechanisms in Fig. 8, the
heat transfer coefficients assume similar values at 342 [rpm].
Above this speed, however, the internal convection increases
much more rapidly. Taking into account the convective area, the
internal heat transfer represents 45.5% of the convective heat
transfer at 342 [rpm], increasing to 55.4% at 1025 [rpm]. This
Fig. 7. Non-dimensionalized temperature vs time for open vented rotor at vari-
ous speeds (r2 location). result illustrates the importance of vented brake rotors in appli-
cations involving moderate speeds above 342 [rpm].
Table 3
Exponential curve fit and internal convective heat transfer coefficients for open 2.5. Analytical comparison
vented rotor
N [rpm] b hconv.i [W m−2 K−1 ]
To validate the experimental results, it was desired to evalu-
ate analytical relations where permitted. While the entire brake
342 0.001448 27.0
684 0.002461 52.7 rotor represents a very complex geometry, the external convec-
1025 0.003442 78.3 tion can readily be determined by considering a solid rotating
disk. Sparrow and Gregg [11] present an analytical solution for
the convective heat transfer from a rotating disk to a fluid. For
transfer coefficients from Table 2, the internal heat transfer co- their analysis, the flow was specified to be laminar while the
efficients were determined and are presented in Table 3. disk was assumed isothermal and immersed in a large volume of
Using the results from Table 2 and 3, Fig. 8 shows the heat quiescent fluid. The resulting analytical expressions were eval-
transfer coefficient versus rotor speed. While only based on uated numerically for a range of Prandtl numbers. The solution
three data points, the sample data correlates well with a lin- states that the external convective heat transfer is proportional
ear fit. Unlike external convection, natural convection for the to the root of the speed, confirming the non-linear relation-
given test setup would be negligible for the internal flow, due ship. Based on the operating conditions and geometry of the
to the horizontal orientation of the rotor. Therefore, for zero disc, the results of the analytical solution are presented in Ta-
rotation, the linear fit predicts zero heat transfer, as would be ex- ble 4. For a rotational speed of 342 [rpm], the analytical and
pected for convection with zero flow rate. Thus, for the range of experimental result correlated well, with 12.7% error. This con-
464 A.D. McPhee, D.A. Johnson / International Journal of Thermal Sciences 47 (2008) 458–467
Table 4
Experimental and theoretical external convective heat transfer coefficients
N [rpm] hexp [W m−2 K−1 ] hthe [W m−2 K−1 ]
342 27.4 23.9
684 40.8 33.8
1025 53.3 41.4
3.1. Experiment
2.6. Conduction and radiation assumptions
To provide greater insight into the internal convective heat
The conductive heat transfer was shown to be minimal dur- transfer, it was desired to both visualize the flow field and quan-
ing testing, as indicated by the near unity coefficients for the tify mean and turbulent properties. To accomplish these results,
exponential curve fits. However, to solidify this assumption, with great accuracy, PIV (particle imaging velocimetry) was
the conductive heat transfer can be evaluated using Eq. (3). utilized.
Based on the thermal conductivity and contact resistance of In this experiment, the test setup from the heat transfer ex-
the 6.35 [mm] asbestos disc, the heat transfer coefficient was periment was used to rotate an identical rotor. However, to vi-
determined to be 0.51 [W m−2 K−1 ]. To evaluate Eq. (3), the sualize the flow field of the internal passages, acrylic windows
temperature difference between the mounting hat and hub was have been installed on the brake rotor as illustrated in Fig. 9.
required, representing a maximum at t0 . During testing, an ini- For complexity reasons, the rotor was not subject to heating for
tial hub temperature of 438 [K] was recorded. Since both con- the PIV measurements. Rather, the flow field was observed un-
duction and radiation are independent of rotor speed, the values der ambient conditions.
would assume a maximum percentage of total heat transfer for To obtain PIV measurements, illumination of the flow
342 [rpm]. With an initial mounting hat temperature of 526 [K] through the passages was provided by a pulsed laser sheet 1–
for 342 [rpm], the maximum conductive heat transfer was deter- 2 mm in thickness, generated by a dual cavity Nd-YAG laser.
mined to be 44.8 [W]. Based on the experimentally determined Vaporized mineral oil was utilized as a seeding particle, to aid
heat transfer coefficient, the total heat transfer is calculated to in the visualization of the flow. To contain the seeding particles,
be 1725.2 [W]. Therefore, at most, conduction represents 2.6% a large acrylic box surrounded the assembly during testing. For
of the total heat transfer. a single acquisition, two images were captured in rapid suc-
Proceeding with a similar analysis for radiation, Eq. (4) cession using a Kodak Megaplus ES 1.0 CCD camera with
was evaluated. Specifying an emissivity of 0.22 [12] for the a resolution of 1008 × 1018 pixels, covering an area of 63
cast iron rotor, the maximum radiation heat transfer, corre- by 63 [mm]. Images were processed using cross-correlation,
sponding to 583 [K], was calculated to be 161.8 [W]. At yielding an instantaneous vector field measuring 62 by 62 data
342 [rpm], the radiation component corresponded to 9.4% of points. Johnson et al. [13] provides a detailed description of the
the total heat transfer. However, due to the fourth power de- PIV setup, cross-correlation routines, and experimental uncer-
pendency on surface temperature, the radiation contribution de- tainty.
cayed very rapidly with time. This discrepancy could partially Similar to the heat transfer experiment, the PIV measure-
account for the predicted non-zero external convection for zero ments were conducted for three nominal speeds of 342, 684,
rotation, which has largely been attributed to natural convec- and 1025 [rpm]. For each, 500 phase locked instantaneous vec-
tion. tor fields were acquired permitting accurate determination of
While the conduction and radiation components represent mean and turbulent flow quantities.
non-negligible contributions at maximum temperatures and
342 [rpm], the impact quickly decays with time. Also, the con- 3.2. Results
tribution at 684 and 1025 [rpm] is much less significant due
to the enhanced convective heat transfer coefficients. Thus, the The velocities returned from the PIV experiments represent
assumption of negligible conduction and radiation has been val- the absolute motion of the fluid, as the velocity measurements
idated. were acquired from a fixed imaging sensor. To analyze the re-
A.D. McPhee, D.A. Johnson / International Journal of Thermal Sciences 47 (2008) 458–467 465
Table 5
Average cross-sectional velocity at exit and total volume flow rate for various
rotor speeds
N [rpm] W̄y [m s−1 ] Q [m3 s−1 ]
342 1.6 0.0074
684 3.4 0.0156
1025 4.6 0.0212
4. Conclusions
With a wealth of experimental heat transfer and flow data, simulation of brake rotor flow field, SAE Technical Paper 952696.
an accurate numerical model could be created to further under- [6] J.J. Zhang, A high aerodynamic performance brake rotor design method
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performance. motive brake rotor, SAE Technical Paper 951116.
[9] F.Z. Shen, D. Mukutmoni, K. Thorington, J. Whaite, Computational flow
analysis of brake cooling, SAE Technical Paper 971039.
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