Abstract: Using Finite Element Method (FEM)-based simulation In ANSYS Workbench, the present work demonstrates an extensive thermal and structural analysis of the grey cast iron disc brake. In particular, the work focuses on the numerical investigation of the residual mechanical behaviour of the composite brake disc through steady state and transient braking conditions to study temperature distribution, thermal stress and deformation behaviour. Grey cast iron was chosen due to its high thermal conductivity, wear resistance, and vibration absorbing characteristics. A mode of the disc brake system was created using a CAD program and placed under a range of braking loads, speeds, and thermal conditions.

Full transient thermal analysis showed the maximum temperatures at the outer radius of the disc, and the steady-state simulation indicated thermal hotspots during extended periods of braking. The structural analysis presented critical stress concentration areas around the inner hub, with a maximum von Mises stress of 2661.8 MPa. The X and Z axis directional deformations revealed considerable dislocation at the outer rims and movement to the respective axis near the hub. This analysis showed that both peripheral and central region were more susceptible to elastic deformation.

The results underline the importance of utilizing dynamic simulations in design validation. These results furnish crucial information needed for the optimization of disc geometry layout, material choices, and structural reinforcements for an improved braking performance, longevity and reliability for automotive applications.

Keywords: Grey Cast Iron, Disc Brakes, Thermal Analysis, Structural Analysis, ANSYS, Steady-State, Transient, FEM

| DOI: 10.17148/IARJSET.2025.12340