International Journal of Engineering Trends and Technology (IJETT) – Volume 35 Number 5- May 2016

Performance Analysis of Various Disc Brake

Profiles
Mr.R.Vijay Krishna*1, Dr.C.Naga Bhaskar#2,
*1
Associate Professor, Mechanical Department, NRI INSTITUTE OF TECHNOLOGY, Agiripalli,
Krishna District, Andhra Pradesh, India.
#2
Professor, Mechanical Department, NRI INSTITUTE OF TECHNOLOGY, Agiripalli,
Krishna District, Andhra Pradesh, India.

Abstract — A Disc brake is a device that with brake disc which creates friction and stops the
retards/halts the rotation of a shaft / wheel. A disc brake disc/rotor to rotate by which the disk brake
brake system consists of a brake disc, a brake system stops or slows down the vehicle.
caliper and brake pads. When the brake pedal is When the brake lever is released the piston ring
applied, pressurized hydraulic fluid squeezes the pushes the caliper piston back to cylinder bore of
brake pad friction material against the surface of the caliper till both, caliper piston and piston ring come
rotating brake disc. The result of this contact into their original shape. At this time retraction
produces friction which enables the vehicle to slow spring pushes the brake pads to their original
down or stop. Due to this friction, heat will be position. The return spring in master cylinder
generated and the brake disc gets heated up which assembly pushes the master cylinder piston back into
affects the performance of the disc brake under its original position and allows the fluid to flow.
different braking conditions.
In this paper focus is primarily emphasized on
the comparative performance of disc brakes having
different profiles, by determining the heat generated
and von-misses stress developed in the brake disc for
different braking conditions using ANSYS 14.5.
Keywords — Brake Disc, Heat Flux, Von-misses
Stress, Performance.

I. INTRODUCTION
A Brake is a device used in the machines to
inhibit the motion by providing artificial frictional
resistance to a moving member. Brake plate absorbs
the kinetic energy and dissipates the heat energy.
There are different types of brakes among which
disc brakes, drum brakes, air brakes, and vacuum
brakes are prominent.
The disk brake is a round, flat piece of metal, Fig 1: Disc Brake plates
made usually of cast iron that is attached to the
wheel. When braking, the brake discs are squeezed
against the wheel on either side by brake pads. Disk
brakes last longer and are more effective when wet
than drum brakes.
A disk brake works on the principle of Pascal‘s
Law/Principle of transmission of fluid pressure. The
fluid enters in to cylinder bore of caliper assembly Fig 2: Disc pads
via brake hosepipes and pushes the caliper piston or
pistons. At this time the piston ring moves in rolling
shape with piston and then the caliper piston pushes
brake pad. This movement causes brake pads to stick

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 International Journal of Engineering Trends and Technology (IJETT) – Volume 35 Number 5- May 2016

II.MESHING & MATERIAL PROPERTIES OF B. Material Properties of Disc Brake Profiles

DISC PROFILES
Name Cast iron
A. Meshing: 1) Thermal co-efficient of expansion 1.7039e-5/C
A mesh is the discretization of a component in to 2) Thermal conductivity 54.0 w/m k
a number of small elements of defined size. These 3) Specific heat 586.0 j/kg k
elements are connected to each other at points called
4) Density of cast iron 7100 kg/m3
nodes. Each node may have two (or) more than two
5) Young‘s modulus 125e9 N/m2
elements connected to it. a collection of these
6) Poisson‘s ratio 0.25
elements is called mesh.
Table – 1: Properties of Disc Plate - 1
Meshing is a very important part of Name Value
pre-processing in any FEA software. In ANSYS 1) Density 2460 kg/m3
workbench there are many tools and options 2) Young‘s modulus 86.9 GPa
available to help you create an effective meshing 3) Thermal conductivity 1.45 W/mk
ANSYS workbench, you can generate mesh with the 4) Specific Heat 737 J/KgK
default settings available when you start the software, 5) Poisson‘s ratio 0.28
and you can also set parameters as per your 6) Coefficient of expansion 0.9*10^6/K
requirement to generate a mesh. Table – 2: Properties of Disc Pads - 1
Name Cast iron
1. Thermal co-efficient of expansion 1.7039e-5/C
2. Thermal conductivity 54.0 W/mK
3. Specific heat 586.0 J/kg K
4. Density of cast iron 7100 kg/m3
5. Young‘s modulus 125e9 N/m2
6. Poisson‘s ratio 0.25
Table – 3: Properties of Disc Plate - 2

Name Value
1. Yield strength 1.72339e+0.008 N/m2
Fig3: IGES Model of Fig4: Meshed Model of 2. Tensile strength 4.13613e+0.008 N/m2
Disc Profile - 1 Disc Profile – 1 3. Elastic modulus 2e+011 N/m2
4. Poisson‘s ratio 0.28
5. Mass density 7800 Kg/m3
6. Shear modulus 7.7e+010 N/m2
Table – 4: Properties of Disc Pads - 2
Name Cast iron
1. Thermal co-efficient of expansion 1.7039e-5/C
2. Thermal conductivity 54.0 W/mK
3. Specific heat 586.0 J/kg K
4. Density of cast iron 7100 kg/m3
5. Young‘s modulus 125e9 N/m2
6. Poisson‘s ratio 0.25
Fig5: IGES Model of Fig6: Meshed Model of
Table – 5: Properties of Disc Plate - 3
Disc Profile - 2 Disc Profile – 2
Name Value
1. Mass density 2500 kg/m3
2. Elastic modulus 165
3. Poisson‘s ratio 0.28
Table – 6: Properties of Disc Pads - 3

III.INPUT DATA
Thermal and structural analysis was performed in
order to know the maximum nodal temperature, total
deformation, total heat flux, equivalent (von-misses)
stress and Frictional shear stress developed on a pad
Fig7: IGES Model of Fig8: Meshed Model of for different rotor material on a different disc brake
Disc Profile - 3 Disc Profile – 3 profiles using Workbench software ANSYS 14.5.

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 International Journal of Engineering Trends and Technology (IJETT) – Volume 35 Number 5- May 2016

A. Analysis IV.TABLES & GRAPHS

LOAD VON -MISSES STRESS

(N) (N/mm2)
0 0
2 71.573
2.5 89.484
3 107.38
Fig 9: Equivalent (Von-Misses) Stress for Disc Plate - 1 3.5 125.28
4 143.17
4.5 161.07
5 178.97
Table 7: Load Vs Von-misses Stress for
Disc brake profile – 1

Fig 10: Heat Flux for Disc Plate - 1

Graph 1: Load Vs Von-misses Stress for

Disc brake profile - 1
Fig 11:Equivalent (Von-Misses) Stress for Disc Plate - 2

LOAD VON -MISSES STRESS

(Pa) (N/mm2)
0 0
2 46.76
2.5 58.45
3 70.14
Fig 12: Heat Flux for Disc Plate - 2 3.5 81.83
4 93.52
4.5 105.21
5 116.9

Table 8: Load Vs Von-misses Stress for

Disc brake profile – 2

Fig 13:Equivalent (Von-Misses) Stress for Disc Plate - 3

Fig 14: Heat Flux for Disc Plate - 3 Graph 2: Load Vs Von-misses Stress for
Disc brake profile - 2

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 International Journal of Engineering Trends and Technology (IJETT) – Volume 35 Number 5- May 2016

LOAD VON -MISSES STRESS

(Pa) (N/mm2) VI. CONCLUSIONS
From the results obtained for Disc Profiles – 1, 2
2 144.07
& 3, it is hereby concluded that:
2.5 180.08 1. Maximum von-misses obtained for Disc Profile
3 216.1 - 1, 2 & 3 are 178.97 N/mm2, 116.9 N/mm2 &
360.16 N/mm2 respectively.
3.5 252.11
2. Maximum heat flux obtained for Disc Profile - 1,
4 288.13 2 & 3 are 62513 W/mm2, 53943 W/mm2 &
4.5 324.15 70701 W/mm2 respectively.
From the above results it is evident that among
5 360.16
three different disc profiles (1, 2 & 3) taken for the
study the Disc Brake Profile - 2 can be used for
Table 9: Load Vs Von-misses Stress for
effective performance.
Disc brake profile – 3
ACKNOWLEDGMENT
The authors are thankful to the anonymous
reviewers for their comments which were very
helpful in improving the quality and presentation of
this paper.
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