COMSOL Disc Brake Simulation

For the final project in my Thermal Fluids System II class, my group and I simulated the airflow and heat transfer over a bike disc brake in COMSOL. We wanted to simulate the difference in airflow and heat transfer over a solid disc versus the standard disc brake design with cutouts in it. This was challenging to set up and simulate in COMSOL due to the rotation of the disc but eventually, we got realistic results.

Through our simulations, we found that the cutout disc brake had higher flow velocities and lower surface temperatures. The cutout disc brake also had a higher heat transfer rate.

We also compared our results to an experiment of airflow and heat transfer over a disc brake and found them to be realistic.

Quantitative findings from our simulations

Based on the table above it is clear that the disc with cutouts has faster air flow over its surface, a higher rate of heat transfer, and a lower surface temperature.

Graph with a slice plot and flow streamlines above the surface of the cutout disc brake run on an extra coarse mesh. Both are colored based on the temperature in Kelvin.

This figure shows how the flow and heat transfer of the rotating disc brake are impacted by the cutouts. Since the slice plot goes through the air and not the disc itself, the graph shows how the air heats up as it goes further over the disc due to the growth of the boundary layer and is interrupted by cutouts in the geometry.

Graph with a slice plot and flow streamlines above the surface of the solid disc brake run on an extra coarse mesh. Both are colored based on the temperature in Kelvin.

This figure shows how the flow and heat transfer of the rotating disc brake behave over a flat surface. Since the slice plot goes through the air and not the disc itself, the graph shows how the air heats up as it goes further over the disc due to the growth of the boundary layer. Unlike the cutout disc brake, the locations of increased temperature are more evenly distributed and continuous.

Meshing

For a more detailed look at our methods, boundary conditions and more in-depth conclusions, the entirety of the report is below.

Lab_4_Report_-_Thermal_Fluid_Systems_II disc brake (1).pdf

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