Ahsanullah University of Science and Technology

Department of Mechanical and Production Engineering

Machine Design Sessional (ME 3202)

Design/Project Title:Braking Mechanism of a Car (Disk

Brake)

Group No: 15
Group Members (With their IDs in parenthesis):
1.NISHAT TASNIM(200108116)
2.ASIF KARIM KHAN(200108126)
3.ABDULLAH AL MASUD(200108140)
4.ANAS AL RAFIN(200108143)
5.ABDULLAH AL ASIF(200108150)
Date of Submission:24/08/2023

Contents
1 Introduction
1.1 Main Objective
1.2 Methodology
2 Design specifications and constraints
3 Research and investigation
4 Alternative designs
5 Choosing and justifying optimal design
6 Developing a prototype
7 Testing and evaluating the design solution
8 Redesigning the solution with modifications
9 Concluding Remarks
9.1 Conclusions
9.2 Recommendations

Appendix
Sustainability
References
Gantt Chart
List of Figure
Figure 01. Solid disk Temperature result 08
Figure 02.Ventilated disk Temperature result 08
Figure 03. Disk 1 09
Figure 04. Disk 2 09
Figure 05. Disk 3 09
Figure 06. Heat dissipation 09
Figure 07. Disk 2’s Heat Dissipation 09
Figure 08. Disk 3’s Heat Dissipation 09
Figure 09. Minimum Heat generation on all three disk 10
Figure 10. Disk 1’s Stress 10
Figure 11. Disk 2’s Stress 10
Figure 12. Disk 3’s Stress 10
Figure 13. Minimum Stress generated by three disk 11
Figure 14.Total Deformation of disk 1 11
Figure 15:Total Deformation of disk 2 11
Figure 16:Total Deformation of disk 3 11
Figure 17.Highest Deformation of disk 12
Figure 18:Technical Drawing 13
Figure 19.Available life Vs Load 16
Figure 20:Equivalent stress Vs Element size(mesh analysis) 16
Figure 21.Topology optimization 17
Figure 22.Life Vs Load Graph 18
Figure 23.Minimum heat generation 18
Figure 24.Highest Deformation 18
Figure 25:Minimum stress developed 18
1. Introduction
1.1 Main Objective

The main objective of this presentation is to provide an in-depth understanding of disk

brake design and its importance in the automotive industry.The primary objective
underpinning the conceptualization and engineering of a disk brake resides in the
efficacious conversion of kinetic energy possessed by a moving vehicle into thermal
energy, thereby effectuating deceleration and eventual cessation of its motion. This
intricate mechanism involves the orchestrated interplay of diverse components,
including but not limited to a rotor (comprising a disc), caliper assembly, and
friction-inducing pads. The dynamic interfacial interaction between the rotating disc and
the stationary caliper generates frictional forces, leading to the transformation of the
vehicle's translational energy into heat, a phenomenon known as kinetic-to-thermal
energy conversion. This dissipation of energy is instrumental in mitigating the vehicle's
velocity, culminating in a controlled and desirable deceleration. The efficacy of this
system is contingent upon factors such as the material composition of the rotor and
pads, the geometric configuration of the components, and the optimal utilization of
thermodynamic principles governing the conversion and dissipation of energy. Thus, the
cardinal objective of the disk brake's design is the intricate orchestration of these
multifaceted dynamics to ensure safe and reliable deceleration of vehicular motion
through the astute manipulation of kinetic and thermal energy principles.

1.2 Methodology

Communicate your achievements

Redesign and solution

Test and Evaluate

Develop a prototype

Choose and justify optimal solution

Generate alternative design

Research and Investigation

Clarify problem specifications and constraints

Under the term Informed Design Process or IDP, we were given a guideline outlining a
series of steps or methods employed to undertake a specific research or project. The
sequential steps are as follows:

1. Problem Specifications and Constraints: The project's foundation lay in

identifying precise design specifications and requisite measurements for the
suspension system. Anticipating potential challenges, we acknowledged possible
obstructions from the outset
2. Research and Investigation: Comprehensive exploration of research papers
and online resources augmented our understanding of the project. This research
phase equipped us with valuable insights that guided our approach.
3. Create alternate designs: Diverse spring designs were conceptualized, each
with distinct wire diameters, mean diameters, and pitches. The intention behind
this step was to achieve minimal stress and deflection, establishing a robust
starting point.
4. Choosing and justifying optimal design: After generating a spectrum of spring
designs with varying wire diameters, mean diameters, and pitches, the design
with the least stress and deflection was identified as the optimal choice.
Justification for this selection was provided through meticulous hand calculations,
referencing resources such as Shigley's book.
5. Prototype creation: The ultimate prototype emerged through a process of
fine-tuning measurements, resulting in a design that embodied our meticulous
efforts.
6. Testing and Evaluation: Thorough simulations were executed on the final
prototype to comprehensively understand its behavior in various scenarios. This
step provided valuable insights into the spring's performance characteristics.
7. Redesign and Solution: Following rigorous testing and evaluation, adjustments
were made to the prototype through a thoughtful redesign process. This ensured
that the suspension system was adept at handling diverse situations by
modifying key measurements.
8. Communicating our achievements: Our successful suspension system design,
optimized to meet the desired specifications and constraints, stands as the
culmination of our endeavor.
2. Design specifications and constraints
2.1 Specifications
Disk Brake need some actuating specifications for further constructing

● Minimum Radius from Center to Brake Pad: This parameter defines the
minimum distance from the center of the brake rotor to the inner edge of the
brake pad. It is critical for ensuring proper engagement and effective braking.
● Maximum Radius from Center to Brake Pad: This specification indicates the
maximum allowable distance from the center of the brake rotor to the outer edge
of the brake pad. It helps prevent any interference with other components and
maintains consistent braking performance.
● Minimum Angle from Disc Pad to Center: The minimum angle between the
braking surface of the pad and the line drawn from the center of the rotor is
crucial for achieving even contact and balanced braking force distribution
● Maximum Angle from Disc Pad to Center: This specification sets the upper
limit for the angle between the brake pad surface and the line connecting the
center of the rotor. It ensures optimal contact and prevents uneven wear on the
braking surface.
● Torque Requirements: The torque required to achieve the desired braking force
must be determined accurately. This factor directly affects the system's braking
efficiency and overall performance.Which is highest 700Nm
● Coefficient of Friction: The coefficient of friction between the brake pad
material and the rotor surface plays a pivotal role in determining the system's
stopping power and heat dissipation capability.Which is 0.7
● Hydraulic Cylinder Diameter: The diameter of the hydraulic cylinder used to
apply the braking force needs to be specified. This measurement affects the
pressure applied to the brake pads and influences the overall braking
performance.Which is 38mm
2.2 Constraints

● Thermal Management: Disk brakes generate a significant amount of heat during

braking due to friction between the brake pads and the rotor. If this heat is not
effectively managed, it can lead to brake fade, reduced braking performance, and
even warping or cracking of the rotor. Engineers need to design cooling
mechanisms, such as ventilation fins, cross-drilled holes, or cooling channels, to
dissipate heat efficiently and maintain stable braking performance.
● Weight and Inertia: The weight of the brake components, including the rotor,
caliper, and pads, affects the overall weight of the vehicle or machinery. A
heavier brake system can increase fuel consumption, reduce acceleration, and
impact the overall handling and performance of the vehicle. Additionally, the
rotational inertia of the brake components can affect how quickly the vehicle can
accelerate and decelerate, so minimizing inertia while maintaining braking
efficiency is crucial.
● Friction and Wear: The friction between the brake pads and the rotor is
essential for converting kinetic energy into heat during braking. However, this
friction also leads to wear of both the pads and the rotor surface. Engineers need
to strike a balance between optimizing the friction for effective braking
performance and managing wear to ensure a reasonable lifespan for the brake
components before they need replacement.
● Cost: The cost of materials, manufacturing processes, and assembly
significantly impacts the overall cost of the brake system. Engineers must
consider cost-effective solutions while still meeting performance and safety
requirements. This involves selecting suitable materials, manufacturing methods,
and design features that maintain a balance between performance and
affordability.
● Rotor Surface Geometry: The shape and surface pattern of the rotor can
influence the brake's performance. Engineers often consider factors such as the
rotor's diameter, thickness, and the presence of slots, holes, or other surface
features. These features can affect heat dissipation, friction characteristics, and
overall braking efficiency.
● Cooling Channels: Efficient cooling is crucial to prevent overheating and
maintain consistent brake performance. Cooling channels can be integrated into
the rotor design to facilitate the movement of air or even cooling fluids through
the brake system. These channels help dissipate heat, reduce thermal stress,
and extend the lifespan of the brake components.
3. Research and investigation
According to the research and investigation paper, an in-depth analysis was performed
to compare the thermal characteristics of solid stainless steel disk brakes and solid cast
iron disk brakes. This analysis aimed to understand the heat dissipation capabilities of
both types of brakes.

Subsequently, the researchers extended their study to include ventilated disk brakes as
well. Both ventilated stainless steel disk brakes and ventilated cast iron disk brakes
were subjected to thorough thermal analysis. The primary objective was to assess the
heat dissipation efficiency and heat generation characteristics of these ventilated brake
variants.Upon conducting the four different analyses, it was determined that the
ventilated cast iron disk brake outperformed the other configurations. Specifically, this
brake design exhibited superior heat dissipation capabilities and demonstrated the
ability to generate the least amount of heat among all the tested configurations. This
conclusion underscores the advantages of utilizing ventilated cast iron disk brakes in
applications where efficient heat management is a critical consideration.
http://www.kresttechnology.com/krest-academic-projects/krest-mtech-projects/Mechanical/Mech%20Mechanical%202016-2017%20abstract%20base%20paper/base%20papers
/7.design%20and%20analysis%20of%20disk%20brake.pdf

Figure 01.Solid disk Temperature result Figure 02.Ventilated disk Temperature result

Table 1.Comparison the result of Solid and Ventilated Disk

 4. Alternative designs
Based on Shigley’s Mechanical Engineering Design by Richard G. Budynas & J. Keith
Nisbett (10th Edition) (pg. 841-844), calculations were done using formulas by varying
node places and keeping the module same for all the designs.

Figure 03.Disk 1 Figure 04.Disk 2

Figure 05.Disk 3

4.1 Thermal analysis of Disk 1,Disk 2 and Disk 3

Thermal analysis was done by taking the highest temperature generation on all disk’s
brake pad area and it is 100 degree celsius.Then we took upon 1 second to see heat
dissipation.

Figure 06.Disk 1’s Heat dissipation Figure 07:Disk 2’s Heat Dissipation

Figure 08:Disk 3’s Heat Dissipation

 Figure 09: Minimum Heat generation on all three disk
So from the graph we can see that disk 1 generates the lowest heat as it should be
because of its orientation.

4.2 Equivalent (Von-mises) Stress Analysis of Disk

1,Disk 2 and Disk 3

Figure 10.Disk 1’s Stress Figure 11.Disk 2’s Stress

Figure 12.Disk 3’s Stress

Here,The stress generated by the brake pad when the car needs to be stopped.The
actuating force is 2.3Mpa.
 Figure 13.Minimum Stress generated by three disk

Stress concentration is higher on the region where bolts and nuts are joined.In three
cases minimum stress generated by disk one
4.3 Total Deformation of Disk 1,Disk 2 and Disk 3
Total deformation is measured through where temperature generates most.

Figure 14.Total Deformation of disk 1 Figure 15:Total Deformation of disk 2

Figure 16:Total Deformation of disk 3

 Figure 17.Highest Deformation of disk

Conduction and convection are vital phenomena for our analysis where thermal gradient
navigates the deformation characteristics of our disks.Here too disk 1 is less in
deformation respect to other two disks.

5. Choosing and justifying optimal solution

For choosing an optimal solution we need to go through the findings of our analysis
Where disk 1 is better in heat dissipation and minimum stress generates on disk 1
too.Not only this but for the lesser thermal gradient,disk 1 produces least deformation
amongst all three disks.
5.1 CHOOSING THE OPTIMAL DESIGN
Here the blue line indicates disk 1 and as we can see it gives slightly better availability
of life in our concern loading parameter between 0.75 to 0.95.
So we can choose disk 1 for further modification.

6. Developing a prototype
6.1 Prototype creation using SOLIDWORKS software
6.2 Technical Drawing

Figure 18:Technical Drawing

6.3 Technical Specification

Minimum diameter from center to brake pad, d i= 89.916 mm

Maximum diameter from center to brake pad, do= 199.898 mm

Minimum angle from disk pad to center, θi = 36°

Maximum angle from disk pad to center, θr= 144°

Diameter of nodules = 10 mm

Thickness of disk = 10 mm

Length from disk center to outer nodule center = 77.724 mm

Length from disk center to inner nodule center, = 59.944 mm

Surface area = 70206.27 mm2

 Material: = Cast Iron

6.3 Fabrication Process

Core making Molding Induction melting Pouring

Proof Machining CNC turning VMC drilling Quality control

● Core Making: The fabrication process begins with the creation of the core, which
serves as the mold's interior shape. Cores are usually made from sand or other
suitable materials and are essential for forming the intricate interior features of
the disk brake.
● Molding: Molding involves placing the core in a mold cavity that replicates the
exterior shape of the desired disk brake. Molten metal will be poured into this
mold to take on the intended form.
● Induction Melting: Induction melting is the method employed to heat the metal
until it reaches its liquid state. This is typically done using an induction furnace,
which uses electromagnetic fields to induce heat within the metal.
● Pouring: Once the metal is molten, it is carefully poured into the prepared mold,
encapsulating the core. The metal cools and solidifies, adopting the shape of the
mold.
● Proof Machining: After the metal has solidified, the partially formed disk brake
undergoes proof machining. This involves removing excess material and refining
the shape to ensure dimensional accuracy and uniformity.
● CNC Turning: Computer Numerical Control (CNC) turning is utilized to further
shape the disk brake. This precision machining technique involves rotating the
brake against a cutting tool to achieve the desired dimensions, surface finish,
and geometrical features.
● VMC Drilling: Vertical Machining Center (VMC) drilling is employed to create
holes and perforations in the disk brake. These holes are crucial for heat
dissipation, reducing weight, and attaching the brake to the vehicle's hub.
● Quality Control: Throughout the entire fabrication process, stringent quality
control measures are implemented. These involve inspection of raw materials,
 dimensional checks, material testing, and other quality assurance procedures to
ensure that the final product meets safety and performance standards.

7.Testing and Evaluation

7.1 Fatigue Sensitivity analysis for varying load
Table 2:Load History and disk’s available life according to to load

This table is generated for varying load up to the failure loading of three disks.So a load
Vs Life graph can give us a sense of acceptability between those three disks.
 Figure 19.Available life Vs Load
Here the blue line indicates disk 1 and as we can see it gives slightly better availability
of life in our concern loading parameter between 0.75 to 0.95.
7.2 Evaluation

Figure 20:Equivalent stress Vs Element size(mesh analysis)

Verification
Found Result is consistent with the mathematical model.Simulation value: 0.528Gpa
Mathematical value:0.502Gpa
Error: 4.92%,which is less than 10% so acceptable.

Validation
As the experimental machines were unavailable, we compared the theoretical
calculation with simulated data

8.Redesigning and Solution

8.1Topology optimization

Figure 21.Topology optimization

Topology optimization is a computational design method used in engineering to find the
optimal material distribution within a given design space, subject to certain constraints,
in order to achieve desired performance goals. The goal of topology optimization is
often to minimize material usage while maintaining structural integrity and meeting
design requirements. The process involves iteratively redistributing material within a
design domain to achieve the best possible performance.
8.2 Thermal,Stress,Deformation and Fatigue sensitivity test
for redesigned

Figure 22.Life Vs Load Graph Figure 23.Minimum heat generation

Figure 24.Highest Deformation Figure 25:Minimum stress developed

In all the cases it is fatigue,temperature rising,Deformation rate,Stress developed

Redesigned Disk 1 is better than initial Disk 1.
9. Concluding Remarks
9.1 Conclusion
The integrated design process has successfully led to the creation of an efficient and
reliable disk brake system. By considering various factors such as mechanical design,
materials selection, thermal analysis, and manufacturability, we have achieved a
well-balanced solution that meets the desired performance and safety requirements.
The iterative nature of the process allowed for continuous refinement and optimization,
resulting in a disk brake that effectively dissipates heat, provides consistent stopping
power, and ensures durability over its operational lifespan. This holistic approach
underscores the significance of integrated design in producing effective engineering
solutions.

9.2 Recommendation
● LIMITATIONS
○ Using Stainless Steel and solid disk may cause higher temperature
generation and deformation rate may increase.So using cast iron
and ventilated disk results in lower temperature generation
○ Removing material may increase the deformation rate which was
done in topology optimization.
● Suggestions
○ Brake pad size is vital for brake disk so pad size should be an
optimized solution.

Appendix
Sustainability
Using solidworks we calculated what percentage of recycled content is left after using
this disk brake for 1 year.
References
1.https://www.akebono-brake.com/english/product_technology/product/automotive/disc/
#:~:text=Disc%20brake%20construction,down%20and%20stopping%20the%20vehicle.
2. https://youtu.be/aCzZdelMS5w
3.http://www.kresttechnology.com/krest-academic-projects/krest-mtech-projects/Mechan
ical/Mech%20Mechanical%202016-2017%20abstract%20base%20paper/base%20pap
ers/7.design%20and%20analysis%20of%20disk%20brake.pdf
4.https://motorbikedrivingschool.com/auto/pros-and-cons-of-disc-brakes/?fbclid=IwAR1s
pWAJDDQBy61AdBJi9M69ndxF00mB21BXabeg8ZyYWyGz_JB-orcZ6GE
5
https://citeseerx.ist.psu.edu/document?repid=rep1&type=pdf&doi=edd11f6aaab2139ce4
9b188565c41b7079207f4b

Gantt Chart