Integrated Thermal–Structural Risk Assessment of Slotted Brake Disc Manufacturing Using FEA and FMEA Techniques

Abstract

Slotted brake discs are widely adopted in high-performance automotive braking systems owing to their superior heat dissipation characteristics and improved wet-weather performance. However, the introduction of slot features creates stress concentration zones that may lead to thermal fatigue, crack initiation, and premature structural failure of the brake disc. This paper presents an integrated Risk Assessment and Method Statement (RAMS) framework that combines Finite Element Analysis (FEA) for thermal and structural simulations with Failure Mode and Effects Analysis (FMEA) for systematic risk assessment and quantification. Temperature distributions and Von Mises stress fields are obtained through coupled computational analysis under realistic braking conditions. Ten critical failure modes are identified and ranked using the Risk Priority Number (RPN) methodology. The parametric study compares solid, six-slot, and eight-slot disc configurations fabricated from grey cast iron (IS 210 Gr. FG 260). The results show that slot geometry significantly reduces peak disc temperature while simultaneously increasing localised stress concentrations at the slot edges. The highest RPN recorded is 144 for slot surface wear, while the eight-slot configuration demonstrates the best thermal performance. The proposed RAMS framework provides a structured approach for brake disc geometry optimisation, manufacturing quality planning, and engineering decision-making.