In this paper, transient coupled thermo-mechanical finite element analysis of a three-dimensional model of braking pairs (brake disk and brake pads) is accomplished in order to estimate temperatures and stresses in brake disk during a braking cycle, including braking and cooling phases, and calculate fatigue life. A nonuniform distribution of temperatures is revealed on the surface of the brake disk, gradually generating surface hot spots and hot bands with temperatures up to 800 °C that lead to an uneven distribution of thermal stresses on the frictional surfaces. According to the simulations, variations in the circumferential stress, which is mainly responsible for the cracking of the brake disk, can reach up to 400 MPa in the hot spot areas, depending on the braking configurations. The numerical results are also used to estimate the fatigue life of brake disk using the Smith–Watson–Topper model. The numerical model demonstrates a high accuracy of fatigue life estimation when evaluated by prior experimental studies, signifying the effects of hot spots in reducing the service life of brake disk. Results of the fatigue life estimation show superiority to the analytical method both in the accuracy of calculation and detection of the failure location.
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