International Journal of Scientific & Engineering Research, Volume 6, Issue 4, April-2015 1954

ISSN 2229-5518

Finite Element Analysis Of Disc Brake

using ANSYS WORKBENCH Software
Shailendra Pratap Gautam1, Sateesh Chandra Yadav1, Salim Akhtar1,Vimlash Sahani1,Sandeep Tiwari1
Deepak Kumar Yadav2 , Shyam Bihari Lal3
1
B .Tech students, Sr.Lecturer, 3Assistant Professor, Department of Mechanical Engineering,
2

Buddha Institute of Technology, GIDA Gorakhpur, India.

shyamfme@gmail.com

ABSTRACT: The aim of this paper was to investigate the structural fields of the solid disc brake during short and urgent
situation braking with structural material. We will take down the value of friction contact power nodal displacement and buckle
for different pressure conditions using analysis software ones the value at the hand we can determine the best suitable
material for the disc brake with higher life distance.Temporary structural analysis of the rotor disc of disc brake is aimed at
investigation in to usage of structural gray cost iron materials is required which improve braking efficiency and provide greater
stability to vehicle. We did this investigation by using WORK BENCH ANSYS 15.0 .

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KEYWORDS: CREO, ANSYS WORK BENCH 15.0.

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thermal conductivity plays a significant role in
handling such heat generated.
1.Introduction
The brakes must be strong enough to stop the 2. Finite Element Analysis using ANSYS
vehicle within a minimum distance in an urgent Finite element method is a numerical method for
situation. The driver must have proper control solving any engineering problem. Because it is
over the vehicle during urgent situation braking the mathematical representation of physical
and vehicle must not skid. The brakes must have problems & it gives the approximate solution &
good antedate characteristics their effectiveness also applicable even if physical prototype not
should not decrease with extended application available . ANSYS is FEA software developed
and thus it demand that the cooling of the brakes by ANSYS . ANSYS involves three stages
should be very efficient. For the analysis of gray preprocessing, solution & postprocessing for
cost iron material of the disc brakes is carried solving problems. Preprocessing stage involves
out for study to structural analysis of disc brake. the preparation of FEM model, element type,
The disc brake is a wheel brake which slows real constant, material property & discretization.
rotary motion of the wheel by the abrasion In Solutions stage ANSYS software
caused by close to brake pads against a brake automatically generates matrices that describe
disc with a set of caliper. The disc brake is the behaviour of each element, assemble them &
frequently made of brake fade. It also allows for computes the unknown values primary field
self-cleaning as dust and water is fearful off, variables such as displacement, temperature etc.
diluting friction difference. During the braking
action, the kinetic energy developed at the wheel
is translated into heat energy, which doesn’t
break up fast profusion into the air stream from 2.1.Procedure for finite element
the brake to the brake disk, as a result, the analysis
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International Journal of Scientific & Engineering Research, Volume 6, Issue 4, April-2015 1955
ISSN 2229-5518

Any analysis to be perform by using finite tetragonal elements with element length of 0.5
element method can be divided into following mm (2262 elements).
steps :
1.Discretization 3.1.3. Meshing of the disc
2.Choosing the solution approximation
The elements used for the meshing of the full
3.Forming the element matrixes and equation
and ventilated disc are tetrahedral three-
4. Assembling the matrixes.
dimensional elements with 10 nodes (iso
5. Finding the unknown
parametric) (Fig.2 and 3).In this reproduction,
6. Interpreting the results
the meshing was developed in the contact zone
(disc-pad).This is important because in this zone
3.1 METHODOLOGY the temperature varies considerably.

3.1.1 Procedure of static analysis

First of all, we have prepared assembly in

CREO for disc brake and save this part in IGES

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formate for Exporting into ANSYS WORK
BENCH 15.0. Import IGES mode in ANSYS
WORK BENCH simulation module then we
apply material (Gray cost iron) for Disc Brake.

3.1.2 Meshing criteria

Element type solid10 node quadratic tetrahedral

Fig.2: Meshing of a full disc in ANSYS

Multiphysics (172103 nodes – 114421
elements)

Figure 1: The 10 – node tetragonal elements

(SOLID 187)
The 10 – node tetragonal elements
(SOLID 187) were used for meshing purpose.
Finite element mesh was generated using

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International Journal of Scientific & Engineering Research, Volume 6, Issue 4, April-2015 1956
ISSN 2229-5518

Fig.3: Meshing of a ventilated disc in ANSYS Poisson’s ratio 0.25

Multiphysics (154679 nodes- 94117 elements)
Specific heat 586 𝑱/𝑲𝒈. 𝑲
Three meshes have been tested with the
convergence tool in ANSYS WORKBENCH Thermal conductivity 54 𝑾/𝒎. 𝑲
Multiphysics. The number of elements forming
each meshing is given in Table 1. Table 2: material properties of grey cast iron

Full disc Ventilated 5.Modeling of Rotor Disc

Number of Number of
Mesh 1 46025 77891 The rotor disc modelling is done in CREO
Mesh 2 114421 94117 software created . It is parametric, feature-based,
Mesh 3 256613 369777 bi-directional associative nature solid modelling
software. The assumptions which are made
Table 1: Number of elements of the two
while modeling the process are given below. The
considered meshs
rotor disc material is measured as homogenous

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and isotropic. The problem area is considered as
4.Material Properties for Disc Brakes
axis- symmetric. Inertia & body force effects are
negligible during the analysis.
The rotor discs are commonly manufactured of
No stress in rotor disc before the application of
grey cast iron. . It is primarily composed of Iron
brake. Brakes are applied on the all 4 wheels.
95%, Carbon 2 to 5%, Silicon 1 to 3%, & also
Rotor disc is of Solid type not ventilated.
contains small percentage of Sulphur,
Thermal conductivity of the material used for
Manganese & Phosphorus. Grey cast iron has
analysis is constant. Only ambient air cooling is
high specific heat capacity & thermal
considered. Specific heat of rotor disc material is
conductivity which makes them suitable for
constant & does not change with temperature
making of rotor disc. Other properties are
young’s Modulus of Elasticity, Torsional
Modulus of Elasticity, Crushing Strength,
Brinell hardness & Endurance Limit.
4.1 The material properties of grey cast iron
are:
Name Grey Cast Iron
Model type Linear Elastic
Isotropic
Default Failure Max von Misses Fig.4: 3D Modeling of Rotor Disc
Criterion Stress
Density 7100 𝒌𝒈/𝒎𝟑

Young modulus 125 𝑮𝑷𝒂

6.Result:
International Journal of Scientific & Engineering Research, Volume 6, Issue 4, April-2015 1957
ISSN 2229-5518

Fig.6: Middle principle Stress

Fig.5: Equivalent stress

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Fig.7:Minimum Principle Stress

Fig.6:Maximum Principle Stress

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International Journal of Scientific & Engineering Research, Volume 6, Issue 4, April-2015 1958
ISSN 2229-5518

Fig.8:Minimum Share Stress Fig.10:Maximum Principle Elastic Strain

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Fig.11:Minimum Principle Elastic Strain
Fig.9:Equivalent Elastic Strain
7. Discussions:
The investigation into utilization of new
materials is needed which get better the braking
efficiency and allow for larger reliability to
vehicle. The suitable fusion combined material
which is lighter than structural steel and has
good modulus of elasticity, yield strength and
density attributes. The low weight, the hardness,
the static features also in case of high pressure
International Journal of Scientific & Engineering Research, Volume 6, Issue 4, April-2015 1959
ISSN 2229-5518

and temperature of the resistance to thermal “Study of the thermal behaviour of dry contacts
shock and the ductility afford long life time of in the brake discs « application of software ansys
the disk brake and maintain off all difficulty v11.0»”
most important of loading, which are typical for [6] Ishwar Gupta1, Gaurav Saxena2, Vikas
the classic grey cast iron brake disks. Modi3 “ Thermal Analysis Of Rotor Disc Of
Disc Brake Of Baja Sae 2013 Car Through
8.Conclusion Finite Element Analysis”
By noticing the Structural analysis results using
gray cost iron stress assesses are within the
permissible stress value. So using gray cost iron
is good for Disc Brake. By observing the
frequency analysis, the vibrations are less for
gray cost iron than other materials since its
natural frequency is less. And also weight of the
gray cost iron reduces almost 2 times when
compared with structural steel since its density is

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minimum. Thereby mechanical efficiency will
be raised. By observing analysis results, gray
cost iron are suitable material for Disc Break as
compare to structural steel.

References:
[1] Abhishek kumar tiwari1, Akhilesh kumar
tiwari1,Pramod yadav1, Harigovind singh
yadav1,Shyam bihari lal2, “Finite Element
Analysis Of Disc Brake By ANSYS
Workbench”
[2] ANSYS HELP FILE (2014), made By
ANSYS Inc. USA .
[3]Thirupathi Chandrupatla, AshokD.Belegundu,
“Introduction to finite element in Engineering”
,2003.
[4] Abhishek kumar tiwari1, Akhilesh kumar
tiwari1,Pramod yadav1, Harigovind singh
yadav1,Shyam bihari lal2, “Finite Element
Analysis Of Disc Brake By ANSYS
Workbench”
[5] A.Belhocine 1 , M.Bouchetara 2

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