Design & Analysis of A Disc Brake
Design & Analysis of A Disc Brake
ABSTRACT:
Disc brake consists of a cast iron disc bolted to the wheel hub and a stationary housing
called caliper. The caliper is connected to some stationary part of the vehicle like the axle casing or
the stub axle as is cast in two parts each part containing a piston. In between each piston and the
disc there is a friction pad held in position by retaining pins, spring plates. The passages are so
connected to another one for bleeding. Each cylinder contains rubber sealing ring between the
cylinder and piston Due to the application of brakes on the disc brake rotor, heat generation takes
place due to friction and this temperature so generated has to be conducted and dispersed across
the disc rotor cross section. The aim of this paper was to investigate the temperature fields and also
structural fields of the solid disc brake during short and emergency braking with four different
materials. The distribution of the temperature depends on the various factors such as friction,
surface roughness and speed. The effect of the angular velocity and the contact pressure induces the
temperature rise of disc brake. The finite element simulation for two-dimensional model was
preferred due to the heat flux ratio constantly distributed in circumferential direction. We will take
down the value of temperature, friction contact power, nodal displacement and deformation for
different pressure condition using analysis software with four materials namely cast iron, cast steel,
aluminum and carbon fiber reinforced plastic. Presently the Disc brakes are made up of cast iron
and cast steel. With the value at the hand we can determine the best suitable material for the brake
drum with higher life span. The detailed drawings of all parts are to be furnished.
Keywords: Ansys, Brake Drum, Disc Brake, Friction Pad, Wheel Hub, Pro-e.
I. INTRODUCTION
CLASSIFICATION OF BRAKES
The mechanical brakes according to the direction of acting force may be divided into the following two
groups:
a) Radial brakes:
In these brakes the force acting on the brakes drum is in radial direction. The radial brakes may be
subdivided into external brakes and internal brakes.
b) Axial Brakes:
In these brakes the force acting on the brake drum is only in the axial direction. i.e. Disk brakes,
Cone brakes.
c) Disc brake
A disk brake consists of a cast iron disk bolted to the wheel hub and a stationary housing called caliper.
The caliper is connected to some stationary part of the vehicle like the axle casing or the stub axle as is cast in
two parts each part containing a piston. In between each piston and the disk there is a friction pad held in
position by retaining pins, spring plates etc. passages are drilled in the caliper for the fluid to enter or leave each
housing. The passages are also connected to another one for bleeding. Each cylinder contains rubber-sealing
ring between the cylinder and piston.
Fig.3 Temperature Fig.4 Directional heat Flux Fig.5 Total Heat Flux
Fig.6 Temperature Fig.7 Directional heat Flux Fig.8 Total Heat Flux
Fig.9 Temperature Fig.10 Directional heat Flux Fig.11 Total Heat Flux
Fig.12 Temperature Fig.13 Directional heat Flux Fig.14 Total Heat Flux
IV. CONCLUSION
The model was modeled by using Pro-E and in the format of IGES which is a readable format of
analysis software. By observing the Structural analysis and Thermal analysis results using Aluminum alloy and
Carbon Reinforced Polymer the stress values are within the permissible stress value. So using Aluminum Alloy
and Carbon Reinforced Polymer is safe for Disc Brake. By observing the frequency analysis, the vibrations are
less for Aluminum Alloy than other two materials since its natural frequency is less. And also weight of the
Aluminum alloy reduces almost 3 times when compared with Alloy Steel and Cast Iron since its density is very
less. Thereby mechanical efficiency will be increased. But the strength of Carbon Reinforced material is more
than Aluminum Alloy. Since the Thermal Analysis also Carbon Reinforced is also permissible. By observing
analysis results, Carbon Reinforced Polymer is best material for Disc Brake.
Future scope:
1. By changing the model dimensions new results can be obtained.
2. By changing the model also better results may obtained.
REFERENCES
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