Batch 7

ASIAN COLLEGE OF ENGINEERING
AND TECHNOLOGY
(Approved by AICTE, New Delhi, Affiliated to Anna University,
Chennai) Kondayampalayam, Coimbatore. – 641 110.
DEPARTMENT OF MECHANICAL
ENGINEERING
ME8682 - DESIGN AND FABRICATION

PROJECT
DESIGN AND SIMULATION ANALYSIS
OF BRAKE DISC
PROJECT GUIDE:
Mr. A.K.KARTHIKEYAN.,M.E.,
Head of the Department,
Department of Mechanical Engineering
Asian College of Engineering and Technology,
Coimbatore - 641 110.
Project Work done by

7153201
14312 –
KAMA
RAJ K
7153201
14317 –
MARA
INTRODUCTION
 A disc brake assembly consists of Disc rotor that rotates with the wheel,
Calliper assembly attached to the steering knuckle, disc pads that are
mounted to the calliper assembly.
 This work shows a heat generation and dissipation of a disc brake of a
vehicle during emergency braking and the following release period.
 Brakes which slows the vehicle and thus transforms kinetic energy into
heat energy which results in heating of the brake disc.
 If the disc overheats the brake pads which fades and it can melt in rare
cases.
6/3/2023 ACET 3
INTRODUCTION
 For automotive use, disc brake discs are commonly made of grey iron. The
SAE maintains a specification for the manufacture of grey iron for
various applications. For normal car and light-truck applications, SAE
specification J431 G3000 (superseded to G10) dictates the correct range
of hardness, chemical composition, tensile strength, and other properties
necessary for the intended use.
 Some racing cars and airplanes use brakes with carbon fiber discs and
carbon fiber pads to reduce weight. The structural steel includes a broad
variety of low carbon and manganese steels. Structural steels also include
minor quantities of significant additions of other elements like Nb, V, Ti
and Al.
6/3/2023 ACET 4
REVIEW OF LITERATURE
 Manjunath and Suresh [1] presented a paper to study the analysis of

thermomechanical behaviour of the brake disc during the braking. The
thermal- structural analysis of disc brake is used to determine the
deformation and the Von Mises stress in the disc for solid and ventilated
disc with two different materials to investigate the performance of the rotor
disc. A comparison between theoretical and analytical results are obtained
from finite element model is done. The obtained values from the
analysis which are less than their allowable values, Hence the suitable
design and material of rotor disc is suggested and based on the
performance, strength and rigidity.
6/3/2023 ACET 5
 N. Balasubramanyam [2] a transient analysis for the thermo-elastic contact

problem of the disk brakes with heat generation is performed using the
finite element analysis. To analyse the thermos-elastic
phenomenon occurring in the disk brakes, heat conduction and elastic
equations are solved. The numerical simulation for the thermo-elastic
behaviour of disk brake is obtained in the repeated brake condition. The
analytical results are presented for the distribution of heat flux and
temperature on each friction surface between the contacting bodies
6/3/2023 ACET 6
 Altai and Jalalifar [7] presented a paper on Analysis of heat conduction in a

disk brake system. The problem is solved analytically using Green's
function approach. An attempt has been made to investigate the suitable
hybrid composite material which is lighter than cast iron and has good
Young’s modulus, Yield strength and density properties. Aluminium base
metal matrix composite and High Strength Glass Fiber composites have a
promising friction and wear behaviour as a Disk brake rotor.
6/3/2023 ACET 7
PROBLEM STATEMENT
The goal/determination of the present work is to structure and investigate plate

rotors made of a dim cast press. Cast Iron materials are utilized to plan the
circle rotors. The rotor is advanced, dependent on a few parameters to get an
ideal structure. Discover the rotor, which has a few qualities which give a
better outcome. The rotor is made in CATIA V5 and imported to ANSYS for
examination. The material used for the rotor is ray cast iron since it having
great property related to temperature.
6/3/2023 ACET 8
OBJECTIVE
The main objectives are

 Brakes must be sufficiently able to stop the vehicle inside a
base separation in a crisis.
 Brakes must have great subterranean insect blur attributes, i.e., their
viability should not diminish with the consistent delayed application.
 They ought to have the well enemy of wear properties.
 The materials which are to be chosen must with-stand high temperatures.
6/3/2023 ACET 9
METHODOLOGY
6/3/2023 ACET 10
DESIGN SPECIFICATION AND
MODELLING
6/3/2023 ACET 11
MODELLING OF DISC ROTOR
6/3/2023 ACET 12
THERMAL ANALYSIS - BEFORE BRAKING
6/3/2023 ACET 13
THERMAL ANALYSIS - AFTER
BRAKING
6/3/2023 ACET 14
RESULT AND
DISCUSSION
 Results clearly show that circular disc has the best temperature drop.
No hole-plain disc shows minimum temperature difference. Surface area
and contact volume of the disk is a small factor.
 This does not affect the temperature difference adversely. Material and hole
design is the governing factor for the heat dissipation. High contact area
and volume constitute for better heat dissipation with better ventilation
designs. Ventilation provide the best mode of heat loss. Circular holes
providing maximum temperature drop. Elliptical holes can be selected at
second best.
6/3/2023 ACET 15
CONCLUSION
 Brake rotor assumes essential job in Braking framework and found to be

cautiously chosen.
 The directed research has started with production of 3DCAD

strong surmised show as a multi-body framework, after that strong
work was created where every single coincided component thought to be
flawlessly inflexible, and in conclusive phase of testing limited
component examination was performed utilizing ANSYS
programming software. Shape factor adversely affects the cooling of the
brake disc.
6/3/2023 ACET 16
CONCLUSION
 This not only helps in uniform thermal distribution. It also restricts growth
of thermal stresses in the rotor. Heat dissipation is a key factor
affecting many engineering parameters.
 These can be addressed with such surface extrusions. Exposing the affected
area to convection also reduces thermal stresses. The proper
performance and disturb the material properties which can cause
devastating effects.
6/3/2023 ACET 17
REFERANCES
1. R.M. Wang and M.K. Surappa, Microstructure and interface structure studies of
SiCp-reinforced Al (6061) metal-matrix composites Materials Science and
Engineering. A, 254 (1-2), (1998), 219-226.
2. Shaoyang Zhang, Fuping Wang, Comparison of friction and wear performances

of brake material dry sliding against two aluminum matrix composites reinforced
with different SiC particles, Journal of Materials Processing Technology 182
(2007) 122–127.
3. T.F. Stephenson et al., Aluminum Hybrid Composites Containing Nickel- Coated

Graphite Particulate, Processing, Properties and Applications of Cast Metal Matrix
Composites, eds. P. Rohatgi and P.A. Khan (Warrendale, PA: TMS, 1996), pp.
6/3/2023 ACET 18
THANK
YOU
6/3/2023 ACET 19

Batch 7

Uploaded by

Copyright:

Available Formats

Batch 7

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Batch 7

Uploaded by

Copyright:

Available Formats

ASIAN COLLEGE OF ENGINEERING

ME8682 - DESIGN AND FABRICATION

Project Work done by

 Manjunath and Suresh [1] presented a paper to study the analysis of

 N. Balasubramanyam [2] a transient analysis for the thermo-elastic contact

 Altai and Jalalifar [7] presented a paper on Analysis of heat conduction in a

The goal/determination of the present work is to structure and investigate plate

The main objectives are

 The materials which are to be chosen must with-stand high temperatures.

 Brake rotor assumes essential job in Braking framework and found to be

 The directed research has started with production of 3DCAD

2. Shaoyang Zhang, Fuping Wang, Comparison of friction and wear performances

3. T.F. Stephenson et al., Aluminum Hybrid Composites Containing Nickel- Coated

You might also like