Parametric Optimization of Coupled Thermal and Structural Analysis of a Brake disc Using Finite Element Analysis

¹ This email address is being protected from spambots. You need JavaScript enabled to view it. , Department of Mechanical Engineering, National Engineering College, Kovilpatti, 628503, Tamil Nadu
² This email address is being protected from spambots. You need JavaScript enabled to view it. , Department of Mechanical Engineering, National Engineering College, Kovilpatti, 628503, Tamil Nadu

^* Corresponding author: This email address is being protected from spambots. You need JavaScript enabled to view it.

Published online: 3 March 2026

Abstract

The objective of this work is to conduct parametric optimizations for the performance of a ventilated brake disc manufactured from structural steel using Finite Element Analysis (FEA) to assess the structural and thermal performance of the brake disc while being subjected to coupled braking loads. The focus of the study is to investigate the response of critical parameters; thermal gradients, applied mechanical stresses, applied contact stresses, and deformation occurring during the braking cycle. Three key geometric parameters (rib thickness, hole diameter, and slot radius) were systematically varied leading to a full factorial design of (126) varying design configurations being created. The main goal was to minimize deformation of the brake disc, while simultaneously improving brake disc structural integrity, safety, and service life. The effects of coupled thermal-structural loading were incorporated into the FEA simulations to best simulate real-world operating conditions. Design Point 28 was determined to be the optimal design configuration from the (126) different designs evaluated.