International Journal of Computer Trends and Technology (IJCTT) volume 4 Issue 7July 2013

ISSN: 2231-2803 http://www.ijcttjournal.org Page 2295

Structural Analysis of Disc Brake Rotor
K.Sowjanya
#1
, S.Suresh
*2

1
M. Tech-(CAD-CAM), Siddharth Institute of Engineering and Technology, Puttur

2
Associate Professor, Siddharth Institute of Engineering and Technology, Puttur


Abstract ---This paper deals with the analysis of Disc Brake. A
Brake is a device by means of which artificial frictional
resistance is applied to moving machine member, in order to
stop the motion of a machine. Disc brake is usually made of
Cast iron, so it is being selected for Investigating the effect of
strength variations on the predicted stress distributions.
Aluminium MetalMatrix Composite materials are selected and
analysed.The results are compared with existing disc rotor. The
model of Disc brake is developed by using Solid modeling
software Pro/E (Creo-Parametric 1.0).Further Static Analysis is
done by using ANSYS Workbench. Structural Analysis is done
to determine the Deflection, Normal Stress ,Vonmises stress.

Key Words: Disc brake, Pro/E(Creo Parametric1.0), ANSYS
Workbench, Finite Element Analysis.
I. INTRODUCTION

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 con-
nected to another one for bleeding. Each cylinder
contains rubber-sealing ring between the cylinder and
piston. A schematic diagramis shown in the figure. Due
to the application of brakes on the car 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. An
investigation into usage of new materials is required
which improve braking efficiency and provide greater
stability to vehicle.

II. DISC BRAKE ROTOR

The Disc brake discs are commonly
manufactured out of grey cast iron. The SAE maintains a
specification for the manufacture of grey iron for various
applications. For normal car and light truck applications,
the SAE specifica-tion is J 431 G3000 (superseded to
G10). This specification dictates the correct range of
hardness, chemical composi-tion, 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. Wear rates
tend to be high, and braking may be poor or grabby until
the brake is hot. The mate-rials used for rotor disc are
explained in detail. It is inves-tigated the temperature
distribution, the thermal defor-mation, and the thermal
stress of automotive brake disks have quite close
relations with car safety; therefore, much research in this
field has been performed.

A) Cast Iron:

Cast iron usually refers to grey cast iron, but
identifies a large group of ferrous alloys, which solidify
with a eutectic. Iron accounts for more than 95%, while
the main alloying elements are carbon and silicon. The
amount of carbon in cast iron is the range 2.1-4%, as
ferrous alloys with less are denoted carbon steel by
definition. Cast irons contain appreciable amounts of
silicon, normally 1-3%, and consequently these alloys
should be considered ternary Fe-C-Si alloys. Here
graphite is present in the formof flakes. Disc brake discs
are com-monly manufactured out of a material called
grey cast iron.

B) Aluminum Metal Matrix Composites:

Aluminum is the most popular matrix for the
metal matrix composites (MMCs). The Al alloys are
quite attractive due to their low density, their capability
to be strengthened by precipitation, their good corrosion
resis-tance, high thermal and electrical conductivity, and
their high damping capacity. Aluminum matrix
composites (AMCs) refer to the class of light weight
high perfor-mance aluminum centric material systems.
The rein-forcement in AMCs could be in the formof
continuous or discontinuous fibers, whisker or
particulates, in volume fractions ranging from a few
percent to 70%. In the last few years, AMCs have been
utilized in high-tech struc-tural and functional
applications including aerospace, defense, automotive,
and thermal management areas, as well as in sports and
recreation.
International Journal of Computer Trends and Technology (IJCTT) volume 4 Issue 7July 2013

ISSN: 2231-2803 http://www.ijcttjournal.org Page 2296

There has been interest in using aluminum
based metal matrix composites for brake disc and drum
mate-rials in recent years. While much lighter than cast
iron they are not as resistant to high temperatures and are
sometimes only used on rear axles of automobiles be-
cause the energy dissipation requirements are not high as
compared to front axle. While the friction and wear of al-
mmc were high speeds and loads the behavior could be
greatly improved beyond that of iron discs, given the cor-
rect match of pad and disc material.

III. MODELING OF DISC BRAKE

It is very difficult to exactly model the brake
disk, in which there are still There always a need of
some assumptions to model any complex geometry.
These assumptions are made, keeping in mind the
difficulties involved in the theoretical calculation and
the importance of the parameters that are taken and
those which are ignored. In modeling we always ignore
the things that are of less importance and have little
impact on the analysis. The assumptions are always
made depending upon the details and accuracy required
in modeling. The assumptions which are made while
modeling the process are given below:
1. The disk material is considered as homogeneous and
isotropic.
2. The domain is considered as axis-symmetric.
3. Inertia and body force effects are negligible during the
analysis.
4. The disk is stress free before the application of brake
5. Brakes are applied on the entire four wheels.
6.The analysis does not determine the life of the disk
brake.
7. The disk brake model used is of solid type
And it is not ventilated type.

A)Material names:

AlMMC1;AluminiumMetal Matrix Composite1
AlMMC2; AluminiumMetal Matrix Composite2
CI:CastIron



Fig:1 Model of disc brake

TABLE:1
PROPERTIES OF MATERIALS USED

IV.FINITE ELEMENT ANALYSIS

The finite element method is numerical analysis
technique for obtaining approximate solutions to a wide
variety of engineering problems. Because of its diversity
and flexibility as an analysis tool, it is receiving much
attention in almost every industry. In more and more
engineering situations today, we find that it is necessary
to obtain approximate solutions to problem rather than
exact closed formsolution. It is not possible to obtain
analytical mathematical solutions for many
PROPERTI
ES
GREY CAST
IRON
Al MMC1 Al MM2

DENSITY,

7100 Kg/m3 2765.2 Kg/m3 2820.6 Kg/m3
YOUNGS
MODULU
S,E
125 GPa 98.5 GPa 113.76 GPa
THERMAL
CONDUCT
IVITY, k
54 W/m.K 181.65 W/m.K 147.95 W/m.K
SPECIFIC
HEAT. Cp
586 J /Kg.K 836.8 J /Kg.K 828.43 J /Kg.K
POSSION
S RATIO,

0.25 0.33 0.35
COEFFICI
ENT OF
EXPANSI
ON,
8.1*10-6/0K 17.5*10-6/0K 16.9*10-6/0K
International Journal of Computer Trends and Technology (IJCTT) volume 4 Issue 7July 2013

ISSN: 2231-2803 http://www.ijcttjournal.org Page 2297
engineering problems. An analytical solutions is a
mathematical expression that gives the values of the
desired unknown quantity at any location in the body, as
consequence it is valid for infinite number of location in
the body. For problems involving complex material
properties and boundary conditions, the engineer resorts
to numerical methods that provide approximate, but
acceptable solutions. The finite element method has
become a powerful tool for the numerical solutions of a
wide range of engineering problems. It has been
developed simultaneously with the increasing use of the
high- speed electronic digital computers and with the
growing emphasis on numerical methods for engineering
analysis. This method started as a generalization of the
structural idea to some problems of elastic continuum
problem, started in terms of different equations.

i) STRUCTURAL ANALYSIS
Structural analysis is the most common
application of the finite element analysis. The term
structural implies civil engineering structure such as
bridge and building, but also naval, aeronautical and
mechanical structure such as ship hulls, aircraft bodies
and machine housing as well as mechanical
components such as piston, machine parts and tools.

ii)TYPES OF STRUCTURAL ANALYSIS:

The seven types of structural analyses in ANSYS. One
can performthe following types of structural analysis.
Each of these analysis types are discussed as follows:
Static analysis
Modal analysis
Harmonic analysis
Transient dynamic analysis
Spectrumanalysis
Buckling analysis
Explicit dynamic analysis
Structural static analysis

A static analysis calculates the effects of steady loading
conditions on a structure, while ignoring inertia and
damping effects such as those caused by time varying
loads. A static analysis can, however include steady
inertia loads (such as gravity and rotational velocity),
and time varying loads that can be approximated as
static equivalent loads (such as static equivalent wind
and seismic loads).



V.RESULTS



Fig:2 Meshed model of Disc Brake



Fig:3 Fixed support
A)Cast Iron

Fig:4 Results obtained fromANSYS Work bench


International Journal of Computer Trends and Technology (IJCTT) volume 4 Issue 7July 2013

ISSN: 2231-2803 http://www.ijcttjournal.org Page 2298
B) Al MMC1:

Fig:5 Results obtained for Al MMC1

C)Al MMC2:

Fig:6 Results obtained for Al MMC2


TABLE:2
COMPARISION OF RESULTS

Material Deformation Normal
stress
Vonmises
stress
CI 0.35193 5.8095 50.334
AlMMC1 0.35229 64.812 211.98
AlMMC2 0.36648 65.345 566.7




VI. CONCLUSIONS
The following conclusions are drawn from the present
work.
1. Static structural analysis is carried out by coupling
the Thermal solution to the structural analysis and
the maximum Von Mises stress was observed to be
50.334 M Pa for CI, 211.98 M Pa for AlMMC1, and
566.7 M Pa for AlMMC2.
2. The Brake disc design is safe based on the Strength
and Rigidity Criteria.
3. Comparing the different results obtained from the
analysis, it is concluded that Cast Iron is the best
possible combination for the present application.

REFRENCES

[1] KENNEDY, F. E., COLIN, F. FLOQUET, A. AND
GLOVSKY, R. ImprovedTechniques for Finite Element
Analysis of Sliding Surface Temperatures.Westbury
House page 138-150, (1984).
[2] LIN , J. -Y. AND CHEN, H. -T. Radial Axis
symmetric Transient Heat Conduction in Composite
Hollow Cylinders with Variable Thermal
Conductivity,vol. 10, page 2- 33, (1992).
[3] BRILLA, J . Laplace Transform and New
Mathematical Theory of Visco elasticity,vol. 32, page
187- 195, (1997).
[4] WANG, H. -C. AND BANERJ EE, P. K..
Generalized Axis symmetric
Elastodynamic Analysis by Boundary Element Method,
vol. 30, page 115-131,
(1990).
[5] ZIENKIEWICZ, O. C. The Finite Element method,
McGraw-Hill, New York,
(1977).
[6] BEEKER, A.A. The Boundary Element Method in
Engineering, McGraw-Hill,
New York, (1992).
[7]FLOQUET, A. AND DUBOURG, M.-C. Non axis
symmetric effects for threedimensional Analyses of a
Brake, ASME J . Tribology, vol. 116, page 401-407,
(1994).