An experimental study on prototype lightweight brake disc for regenerative braking

Abstract

Regenerative braking (RB) will minimize duty levels on the brakes, giving advantages including extended brake rotor and friction material life and, more significantly, reduced brake mass and minimised brake pad wear. Thermal performance was a key factor which was studied to measure disc surface temperature using chassis dynamometer in a drag braking with constant speed. The experimental work presented here to find friction coefficient and heat transfer coefficient, and evaluate temperatures for a ventilated brake disc and for a prototype lightweight disc using a Rototest chassis dynamometer. Heat transfer coefficient and friction coefficient of friction material can be determined from cooling analysis. The results from experiments on a prototype lightweight brake disc were shown to illustrate the effects of RBS/friction combination in terms of weight reduction. The design requirement, including reducing the thickness, would affect the temperature distribution and increase stress at the critical area. Based on the relationship obtained between rotor weight, and thickness, criteria have been established for designing lightweight brake discs in a vehicle with regenerative braking.