Braking plays a critical role in Formula Student vehicles, where components must handle intense heat and mechanical loads during rapid deceleration. The brake disc is especially affected, experiencing high temperatures and stresses that can influence performance and durability.
In this study, the initial phase of the simulation involved analysing a plain, solid brake disc model without any ventilation channels, slots, or geometric complexities. 
This baseline analysis was carried out using the 3DEXPERIENCE platform 

This analysis was carried out in 2 steps:- 

1. Step 1:- 0.001s

2. Step 2:- 0.025s

Roles Used:- 

1. Part Design. 

2. Assembly Design.

3. Structural Model Creation.

4. Mechanical Scenario Creation. 

Material Used:- SS410

Post Processing :- Vaccum Hardening 36 HRC

Physics Manager:- 

Mesh Properties:-

Result:-

Von Mises Stress:-

The Von-Mises Stress around the the rotor is 3.39x10^9 N/m^2 which is too high and unacceptable but the rotor has been made intentionally but the stresses generated on rotor is 5.88x10^8 which is 588 MPa which is under safe limit.

Conclusion:-

The coupled thermal–stress analysis of the brake disc shows that the maximum Von Mises stress reaches 5.88 × 10⁸ N/m² (588 MPa). When compared with the mechanical properties of hardened SS410 at 36 HRC, which provides an ultimate tensile strength of approximately 1100–1200 MPa and a yield strength of 850–950 MPa, the results indicate that the disc operates safely within the material’s strength limits. The stresses remain below both the yield and ultimate values, confirming that no permanent deformation or structural failure is expected under the evaluated braking conditions. Overall, the analysis validates the suitability of hardened SS410 for the brake disc design and demonstrates that the disc can withstand the combined thermal and mechanical loads effectively.