Static Structural Analysis of Vented and Non Vented Disc Brake

International Journal of Trend in Scientific Research and Development (IJTSRD)
Volume 3 Issue 5, August 2019 Available Online: www.ijtsrd.com e-ISSN: 2456 – 6470
@ IJTSRD | Unique Paper ID – IJTSRD26450 | Volume – 3 | Issue – 5 | July - August 2019 Page 721
Static Structural Analysis of Vented and Non Vented Disc Brake
Meesala Vanajakshi1, Pothuraju. V. V. Satyanarayana2, E. Lakshmi Devi3
1Post Graduate Student, 2,3Assistant Professor
1,3Department of Mechanical Engineering, Visakha Technical Campus, Narava, Visakhapatnam, India
2Department of Mechanical Engineering, Avanthi Institute of Engineering and Technology,
2Makavarapalem, Visakhapatnam, India
How to cite this paper: Meesala
Vanajakshi | Pothuraju. V. V.
Satyanarayana | E. Lakshmi Devi "Static
Structural Analysis of Vented and Non
Vented Disc Brake" Published in
International
Journal of Trend in
Scientific Research
and Development
(ijtsrd), ISSN: 2456-
6470, Volume-3 |
Issue-5, August
2019, pp.721-727,
https://doi.org/10.31142/ijtsrd26450
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ABSTRACT
The current study essentially deals with the modeling and analyzing vented
and non vented disc brake by CATIA and ANSYS. Finite element models of the
brake-disc are shaped with CATIA and simulated using ANSYS which is based
on the finite element method. This study Structuralanalysisisdonesoastoget
the strength of the disc brake. Here we discuss disc brake which is used in
many vehicles. The stresses and variations developed in vented and non-
vented disc brakes are discussed using ANSYS software. Disc gets stressed
when used in slowing down or stopping the vehicle. So that by using Ansyswe
can observe variations between stresses of vented and non-vented discbrake.
Disc brakes are mostly used on front wheels in two-wheelers, hatchback cars
and also widely used on both front and rear wheels of high end cars.
The main aim of this paper is to minimize the Total deformation, Directional
deformation, Equivalent stress and strain with best suited MaterialAnalysisis
done on both Vented and non vented disc brake. The Geometry of the models
is carried out in the CATIA V5 R20 Software and is designed in Mechanical
Design. The analysis part is done by using ANSYS R14.5 Software.
KEYWORDS: vented, Non vented, hatchback, Catia and Ansys
1. INTRODUCTION
A vehicle requires a brake system to stop or adjust its speed with changingroad
and traffic conditions. The basic principle used in braking systems is to convert
the kinetic energy of a vehicle into some other form of energy.
For example, in friction braking it is converted into heat, and
in regenerative braking it is converted into electricity or
compressed air etc. During a braking operation not all the
kinetic energy is converted into the desired form, e.g. in
friction braking someenergy mightbe dissipated in the form
of vibrations.
So to get optimum performance in demanding applications,
ventilation is introduced in the brake discs which increases
the cooling rate. Brake discs could be divided into two
categories:
1. Ventilated disk brake
2. Non-Ventilated or Solid disk brake
2. PRINCIPLE OF BRAKING SYSTEM
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. Break play a major role in
moving automotive vehicles.
A disk brake consists of a cast iron disc bolted to the wheel
hub and a stationary hosing called caliper the caliper is
connected to some stationary partof the vehicle like the axle
casing or stub axle as in two parts each part containing a
piston. in between each piston and thedisc,thereisafriction
pad held in position by retaining pins, spring plates etc.
passages are drilled in the caliper for the fluid enter or leave
each housing the passages arealso connectedtoanotherone
for bleeding. Each cylinder and piston.
When the brakes are applied, hydraulically actuated pistons
move the friction pads into contact with the rotating disc,
applying equal and opposite forces on the disc. Due to the
friction between disc and pad surfaces the kinetic energy of
the rotating wheel is converted into heat, by which vehicleis
to stop after a certain distance. On releasing the brakes the
brakes rubber-sealing ring acts as return spring and retract
the pistons and the friction pads away from thedisc.
3. DESIGN OF DISC BRAKE
Designing of vented and non vented disc brake rotor using
the ISO standard dimensions of BMW car in CATIA V5.
Fig 1: Three Dimensional Vented Disc brake
IJTSRD26450

International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470
Fig 2: Three Dimensional Non Vented Disc brake
4. DESIGN CALCULATION BENDING TEST
The bending moment to be imparted in the test shall be in
accordance with the following formula:
M = ((μ*R) + d)* F * S
M = Bending moment in ‘Nm’
μ = Friction Coefficient between the tire and the road
surface(no units)
R = Radius of the tyre applicable to the wheel in ‘m’ d =
Offset of the wheel in ‘m’
F = Maximum load acting on the tire in ‘N’ S = Coefficient
specified according to the standards.
Tyre specification Radial 315/60-R18
315 is the section width in millimeters 60 is the Aspect ratio
in percentage
R is the construction type i.e., Radial 18 is the rim diameter
in inches
Aspect ratio = section height / section width
Section height = Section width * Aspect ratio
= 315 * 0.60
= 189 mm
= 0.189 m
Rim radius = 144 mm
= 0.144 m
Tyre radius = Rim Radius + Section height
= 0.144 + 0.189= 0.333 m
According to the industrialstandards:
μ = 0.7 R=0.333m
d = 37 mm = 0.037m F=1400lbs
= 1400 * 0.453
= 634.2 kg
= 634.2 * 9.81
= 6221.5 N
S = 1.5
Bending moment
M = ((μ*R) + d)* F * S
= ((0.7 * 0.333) + 0.037) * 6221.5 * 1.5
= 2520.65 Nm
= 252065Nmm
5. MATERIAL SELECTION
It plays an important role in product design and manufacturing. This is guided by thewaythematerialbehavesin thereal-time
conditions according to its use. The material response to the environmental stimulus is called property. Based on the
application and usage of material, its properties become significant.
Properties Gray Cast Iron Titanium Alloy Stainless Steel
Density 7.2e-006 kg mm^-3 4.62e-006 kg mm^-3 7.75e-006 kg mm^-3
Young's Modulus 1.1e+005 MPa 96000 MPa 1.93e+005 MPa
Poisson's Ratio 0.28 0.36 0.31
Coefficient of Thermal Expansion 1.1e-005 C^-1 9.4e-006 C^-1 1.7e-005 C^-1
Specific Heat 4.47e+005 mJ kg^-1 C^-1 5.22e+005 mJ kg^-1 C^-1 4.8e+005 mJ kg^-1 C^-1
Thermal Conductivity 5.2e-002 W mm^-1 C^-1 2.19e-002 W mm^-1 C^-1 1.51e-002 W mm^-1 C^-1
Resistivity 9.6e-005 ohm mm 1.7e-003 ohm mm 7.7e-004 ohm mm
STATIC STRUCTURAL ANALYSIS
Workbench allows you to copy systems in order to efficiently perform and compare multiple similar analyses.
Staticanalysis is performed over astructure when the loads and boundary conditionsremainstationaryanddonotchangeover
Time. it is assumed that the load or field conditions are applied gradually.
6. RESULTS
TESTING AND VALIDATION OF VENTED & NON VENTED DISC BRAKE CROSS SECTION
MATERIAL MODEL
TOTAL DEFORMATION
(mm)
EQUIVALENT STRESS
(Mpa)
EQUIVALENT STRAIN
GRAY CAST IRON
VENTED 0.0045958 8.9412 8.2068e-5
NON VENTED 0.051897 17.901 0.0001646
TITANIUM ALLOY
VENTED 0.0054448 8.7275 9.1893e-5
NON VENTED 0.055934 17.32 0.00018267
STAINLESS STEEL
VENTED 0.002654 8.8766 4.6457e-5
NON VENTED 0.028952 17.707 9.2832e-5
Tab 1: Comparison results for static structural Ansys

Graph 1: Deformation of different disc brake models
6.1. STATIC ANALYSIS OF DISK BRAKE FOR VENTED
MODELS RESULTS AND ANALYSIS OFVENTEDDISC
BRAKE
Fig 3: Geometry Diagram
Fig 4: Mesh diagram
1. GRAY CAST IRON
Mass= 8.4311kg, Nodes= 34213, Elements=18347.
Fig 5: Total deformation
Fig 6: Equivalent stress

Fig 7: Equivalent Elastic strain
2. TITANIUM ALLOY
Mass= 5.4099 kg, Nodes= 34213, Elements= 18347.
3. STAINLESS STEEL
Mass= 9.0751 kg, Nodes= 34213, Elements= 18347.

6.2. STATIC ANALYSIS OF DISC BRAKE FOR NON
VENTED MODELSRESULTS AND ANALYSIS OF NON
VENTED DISC BRAKE
Fig 14: Geometry Diagram
Fig 15: Mesh diagram
1. GRAY CAST IRON
Mass= 3.657kg, Nodes= 16537, Elements= 7967.

2. TITANIUM ALLOY
3. STAINLESS STEEL

7. CONCLUSION
It is observed that the Vented type disc brakes can provide
better Static Structural analysis than the Non Vented disc
Brake. It provides usefuldesigntoolsandimprovementofthe
brake performance in thedisk brake system. We can say that
from all the values obtained from the analysis i.e. the Total
Deformation, Equivalent StressandEquivalentstrain.exhibit
that the vented disc is best-suited design. Comparing the
different results obtained from the analysis, it is concluded
that disk brake with vents and of material Stainless steel is
observed best possible combination for the present
application.
The finite element results show that the performance of disc
brake used in this study of geometry and materialproperties.
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