Thermoelastic Modeling of Self-Energizing Carbon-Carbon (C/C) Wedge Brakes for High-Performance Race Vehicles

This study investigates amplified hydraulic braking systems employed in high-performance motorsport applications, utilizing wedge mechanisms for self-energization. An analytical expression for the gain coefficient is derived from a simplified equilibrium analysis of the wedge-shaped pad, capturing the nonlinear dependency on both wedge angle and effective mean disc-pad friction. A previously validated coupled thermoelastic model for carbon-carbon (C/C) braking systems—developed in Dymola and Modelica using the finite volume method (FVM) and an analytical local friction formulation—is here adapted to wedge-amplified braking systems, with the aim of providing performance assessment during the design phase of new calipers at reduced computational cost compared to coupled thermoelastic finite element method (FEM) models. Several caliper configurations featuring different wedge angles are tested experimentally on a dynamometer. A reduction in the effective friction coefficient at high mean effective contact pressure—induced by pronounced wedge angles and reduced pad areas—is observed. To validate the thermoelastic model, simulated braking torque and disc surface temperature are compared against bench data. The model shows satisfactory predictive capability under various operating conditions and test cycles, with mean error indices on peak torque prediction below 5% for the majority of the simulated cases. Finally, the validated model is used to virtually assess the performance of a new caliper prototype prior to its manufacturing and testing.