The investigation of optimum material for small and medium-speed vehicle brake discs: a study of heat flux

The braking system is a critical safety component in land vehicles, relying on efficient deceleration during operation. Among its elements, the brake disc plays a central role in dissipating the heat generated by frictional forces during braking. Selecting an optimal disc material with strong thermal performance is therefore essential. This study employs ANSYS steady-state simulations to compare the thermal behavior of three brake disc materials: gray cast iron, titanium grade 5, and an aluminum metal composite. The results show that gray cast iron demonstrates superior heat-dissipation capability – dissipating approximately 8–10 % more heat flux than the other materials tested – making it the most suitable option for small- and medium-speed vehicle brake discs. These findings provide practical insights for automotive engineers and manufacturers seeking to design more reliable and thermally efficient braking systems.