Energy thrift and improved performance achieved through novel railway brake discs

A disc with radial vanes and circumferential pillars proves to be successful in operation and achieves energy efficiency improvements compared with those of traditional design. Cooling characteristics of this novel design are practically identical to the disc with tangential vanes but the equivalent aerodynamic (air pumping) losses are approximately 50% less. It is shown that these reductions in pumping losses can lead to substantial energy savings in train operations.When developing new designs and/or comparing different railway disc designs, the proposed disc cooling to aerodynamic efficiency ratio (ηv) was found to be a very useful parameter to assess. This ‘efficiency ratio’ – a ratio of convective power dissipation to aerodynamic power losses can help in achieving adequate balance of cooling efficiency and aerodynamic losses to suit particular application. The use of CFD is of enormous benefit in generating discs that fulfil these demanding requirements, with the spin rig being exceptionally useful for experimental work.