DESIGN AND ANALYSIS OF DISC BRAKE

TABLE OF CONTENTS

CHAPTER
NO TITLE PAGE NO

ABSTRACT vi
1 INTRODUCTION 1
1.1. DISC BRAKE 1
1.2. PROBLEMS ON DISC BRAKE 2
1.3. LITERATURE SURVEY 3
1.4. AIM AND SCOPE OF STUDY 3
2 SOLIDWORKS 4
2.1. INTRODUCTION 4
2.2. THE STEPS TO CREATE MODEL 5
2.3. TRANSFORMATION OF MODEL 9
3 SELECTION OF MATERIALS 10
3.1. GRAY CAST IRON 10
3.2. ALUMINIUM ALLOY 11
3.3. CARBON FIBER 12
4 ANSYS 13
4.1. INTRODUCTION TO ANSYS 13
4.2. FINITE ELEMENT ANALYSIS 14
4.3. STUCTURAL ANALYSIS 16
4.4. STUCTURAL ANALYSIS PROCEDURE 18
4.5. THERMAL ANALYSIS PROCEDURE 20
5 RESULTS 22

1
 5.1. RESULT FOR GREY CAST IRON 22
5.2. RESULT FOR GREY ALUMINIUM ALLOY 25
5.3. RESULT FOR CARBON FIBER 28
5.4. COMPARISION OF RESULTS 31
6 CONCLUSION 32

REFRENCES 33

2
 LIST OF TABLES
TABLE
NO TITLE PAGE NO
MECHANICAL PROPERTIES
3.1 GRAY CAST IRON 10
3.2 ALUMINIUM ALLOY 11
3.3 CARBON FIBER 12

RESULTS
5.1 GRAY CAST IRON 31
5.2 ALUMINIUM ALLOY 31
5.3 CARBON FIBER 31

3
 LIST OF FIGURE
FIG
NO TITLE PAGE NO

2.1 DISC BRAKE ROTOR MODEL 9

2.2 DIMENSIONS OF DISC BRAKE 9
2.3 IGES FORMATTED DISC 9

4.1 INPUT VALUES OF DISC BRAKE 21

RESULTS

GREY CAST IRON

5.1 DISPLACEMENT 22
5.2 EQUALENT ELASTIC STRAIN 23
5.3 EQUALENT STREES 23
5.4 TEMPERATURE 24
5.5 HEAT FLUX 24

ALUMINIUM ALLOY

5.6 DISPLACEMENT 25
5.7 EQUALENT ELASTIC STRAIN 26
5.8 EQUALENT STREES 26
5.9 TEMPERATURE 27
5.10 HEAT FLUX 27

4
 CARBON FIBER

5.11 DISPLACEMENT 28
5.12 EQUALENT ELASTIC STRAIN 29
5.13 EQUALENT STREES 29
5.14 TEMPERATURE 30
5.15 HEAT FLUX 30

5
 ABSTRACT

Each single system has been studied and developed in order to meet safety
requirement. Instead of having air bag, good suspension systems, good handling
and safe cornering, there is one most critical system in the vehicle which is brake
systems. Without brake system in the vehicle will put a passenger in unsafe
position. Therefore, it is must for all vehicles to have proper brake system.
The standard disc brake of two wheelers model using in Ansys and done the
Thermal analysis and Modal analysis also calculate the deflection and Heat flux,
Temperature of disc brake model. This is important to understand action force and
friction force on the disc brake new material, how disc brake works more
efficiently, which can help to reduce the accident that may happen in each day.

The suitable material for the braking operation is selected and all the values
obtained from the analysis are less than their allowable values. Hence the brake
Disc design is safe based on the strength and rigidity criteria. By identifying the
true design features, the extended service life and long term stability is assured.

6
 CHAPTER 1
INTRODUCTION
1.1.DISC BRAKE
A 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 etc. passages are drilled in the caliper
for the fluid to enter or leave each housing. The passages are also connected to
another one for bleeding. Each cylinder contains rubber-sealing ring between the
cylinder and piston. A schematic diagram is shown in the figure 1.1.
The main components of the disc brake are:
The Brake Pads
The Caliper which contains the piston
The Rotor, which is mounted to the hub

When the brakes are applied, hydraulically actuated pistons move the friction pads
in to contact with the rotating disc, applying equal and opposite forces on the disc.
Due to the friction in between disc and pad surfaces, the kinetic energy of the
rotating wheel is converted into heat, by which vehicle is to stop after a certain
distance. On releasing the brakes the brakes the rubber-sealing ring acts as return
spring and retract the pistons and the friction pads away from the disc.

SWINGING CALIPER DISC BRAKE:

The caliper is hinged about a fulcrum pin and one of the friction pads is fixed to
the caliper. The fluid under pressure presses the other pad against the disc to apply
the brake. The reaction on the caliper causes it to move the fixed pad inward

7
slightly applying equal pressure to the other side of the pads. The caliper
automatically adjusts its position by swinging about the pin.

SLIDING CALIPER DISC BRAKE:

These are two pistons between which the fluid under pressure is sent which presses
one friction pad directly on to the disc where as the other pad is passed indirectly
via the caliper.

1.2 PROBLEMS IN DISC BRAKE

Friction brakes act by generating frictional forces as two or more surfaces
rub against each other. The stopping power or capacity of a friction brake depends
on the area in contact and coefficient of friction of the working surfaces as well as
on the actuation pressure applied. Wear occurs on the working surfaces, and the
durability of a given brake (or service life between maintenance) depends on the
type of friction material used for the replaceable surfaces of the brake.
We introduced superimpose variation cut pattern on the disc in disc brake. The
numbers of cuts Pattern introduce in disc are evaluated. If the number of cut is
increase in the disc, the area of contract between the disc and pads were reduces, so
efficiency of brake is high. The number of cut was increase the strength of the disc
also reduces. So it can easily break. So the number of cuts in the disc with in the
limit, It can help to Heat transfer rate of the disc and the area of contact between
Disc and Pads are not reduces and efficiency of brake must be same.

8
1.3 LITERATURE REVIEW
Disc-style brakes development and use began in England in the 1890s. The
first caliper-type automobile disc brake was patented by Frederick William
Lanchester in his Birmingham, UK factory in 1902 and used successfully on
Lanchester cars. Compared to drum brakes, disc brakes offer better stopping
performance, because the disc is more readily cooled. As a consequence discs are
less prone to brake fade; and disc brakes recover more quickly from immersion
(wet brakes are less effective). Most drum brake designs have at least one leading
shoe, which gives a servo-effect. By contrast, a disc brake has no self-servo effect
and its braking force is always proportional to the pressure placed on the brake pad
by the braking system via any brake servo, braking pedal or lever. This tends to
give the driver better "feel" to avoid impending lockup. Drums are also prone to
"bell mouthing", and trap worn lining material within the assembly, both causes of
various braking problems.
Sok Won Kim investigated the temperature distribution, the deformation,
and the stress of automotive brake disks have quite close relations with car safety;
therefore, much research in this field has been performed. Xiangie Meng based on
the review of researches on the vibration and noise related to automobile brake, the
four degrees of freedom nonlinear dynamics model of brake disk and pads is
established, the stability of vibration system at the equilibrium points is analyzed.
1.4 AIM AND SCOPE OF STUDY
1. The given disc brake of its stability and rigidity
2. Analysis and structural analysis is carried out on a given disc brake.
3. Best design shape of disc brake like Cutting pattern in disc and material there
by a best combination is suggested.
4. And the best combination of parameters of disc brake is optimistic by a best is
suggested.

9
 CHAPTER-2
INTRODUCTION TO SOLIDWORKS

2.1 INTRODUCTION
The SolidWorks® CAD software is a mechanical design automation
application that lets designers quickly sketch out ideas, experiment with features
and dimensions, and produce models and detailed drawings.
CONCEPTS
Parts are the basic building blocks in the SolidWorks software. Assemblies contain
parts or other assemblies, called subassemblies. A SolidWorks model consists of
3D geometry that defines its edges, faces, and surfaces. The SolidWorks software
lets you design models quickly and precisely.
SolidWorks models are:
• Defined by 3D design
• Based on components
3D DESIGN
SolidWorks uses a 3D design approach. As you design a part, from the initial
sketch to the final result, you create a 3D model. From this model, you can create
2D drawings or mate components consisting of parts or subassemblies to create 3D
assemblies. You can also create 2D drawings of 3D assemblies. When designing a
model using SolidWorks, you can visualize it in three dimensions, the way the
model exists once it is manufactured.

COMPONENT BASED
One of the most powerful features in the SolidWorks application is that any change
you make to a part is reflected in all associated drawings or assemblies.

10
CREATING A SOLID MODEL
Modeling provides the design engineer with intuitive and comfortable
modeling techniques such as sketching, feature based modeling, and dimension
driven editing. An excellent way to begin a design concept is with a sketch. When
you use a sketch, a rough idea of the part becomes represented and constrained,
based on the fit and function requirements of your design. In this way, your design
intent is captured. This ensures that when the design is passed down to the next
level of engineering, the basic requirements are not lost when the design is edited.
The strategy you use to create and edit your model to form the desired object
depends on the form and complexity of the object. You will likely use several
different methods during a work session. The next several figures illustrate one
example of the design process, starting with a sketch and ending with a finished
model. First, you can create a sketch “outline" of curves. Then you can sweep or
rotate these curves to create a complex portion of your design.
INTRODUCTION OF DRAFTING
The Drafting application is designed to allow you to create and maintain a
variety of drawings made from models generated from within the Modeling
application. Drawings created in the Drafting application are fully associative to
the model. Any changes made to the model are automatically reflected in the
drawing. This associativity allows you to make as many model changes as you
wish. Besides the powerful associativity functionality, Drafting contains many
other useful features including the following:
An intuitive, easy to use, graphical user interface. This allows you to create
drawings quickly and easily.
A drawing board paradigm in which you work "on a drawing." This approach is
similar to the way a drafter would work on a drawing board. This method greatly
increases productivity.

11
2.2 THE STEPS TO CREATE THE MODEL AND ASSEMBLY SECTION IS
GIVEN BELOW.
CREATE THE NEW PART-
A part is the basic building block in the SolidWorks software. In this procedure,
you open a new part document where you will build a model.
1. Click New (Standard toolbar) or File > New.
2. In the New SolidWorks Document dialog box, click Part and click OK.
A new part document opens.
SKETCH- This command is used to create the new sketch like circle, line,
rectangle, ellipse, etc,
The SOLIDWORKS window selects the sketch icon and selects the plane or
surface want to sketch.
CIRCLE- This command is used to create the circle. Create circle by picking the
center point and a point on the circle from Right Tool chest.
Pick the origin for the circle’s center - pick a point on the circle’s edge- click ok
ELLIPSE- This command is used to create the ellipse. Create ellipse by picking
the center point and a minor radius point and major radius point, the minor and
major radius of the ellipse is vertical and horizontal direction depend upon the
shape of ellipse we want.
Select the ellipse icon from right tool chest- Pick the center for the ellipse – pick
the minor radius of ellipse point and pick the major radius of the ellipse- click the
middle mouse button – ok
LINE- This command is used to create the line. Create the line by start point and
end point.
ARC- This command is used to create the arc. Create the arc by using three points.
The three points are start point, end point and center point of the arc.
Select the arc icon from the upper Tool chest – click the start point of the arc –

12
click the end point of the arc and click the middle point of the arc –enter.
The dimension of the arc is modified by double click on the arc then the dimension
will appear in the pop up box, then provide the value of the arc.
RECTANGLE- This command is used to create the rectangle and square.
Click the rectangle icon in the right Tool chest – click the lower left point of the
rectangle and higher right corner of the rectangle we want to draw.
After drawing the rectangle the dimension of the rectangle is provided by the pick
the dimension command from the dimension icon in the right tool chest of the pro-
e software.
DIMENSION- This command is used to provide the dimension of the sketched
entities the entities may be circle, line, rectangle, ellipse, etc,
The dimension is provide to the sketch by select the dimension icon from the
right tool chest then select the sketched entities and press the middle mouse button
to finish the dimensioning.
To change the dimension of the sketched entities by just double clicks the
dimension line of created sketch.
EXTRUDE – This command is used to create the material (to make 3D object
from 2D sketch) from the sketched entities. The entities may be circle, line or
rectangle, etc,...
Select the extrude icon from the right tool chest then select the sketched part
in the window, enter the extrude length and press the middle mouse button to finish
the extrude command. There is a provision for removing material in pro –e which
is called cut. The main condition to create the solid model is the sketched section
must be closed.
REVOLVE- This command is used to create the material from taking the one axis
and sketched entities. The axis is the center of the revolved part. The revolve angle
should between 0 degree to 360 degree.
Select the revolve icon from the right toolchest then select the sketched part

13
and axis of the object in the graphical window, enter the revolve angle and press
the middle mouse button to finish the extrude command.
MOVING A COMPONENT
When you insert components into an assembly, you may want to move them so
they do not overlap. By moving the components, it is easier to select them when
you mate the components.
1. Click Move Component (Assembly toolbar) or Tools > Component > Move.

ROTATING A COMPONENT
1. Click the Move Component arrow (Assembly toolbar) and click Rotate
Component or click Tools > Component > Rotate.

DISC BRAKE ROTOR MODEL CREATED BY USING SOLIDWORKS

SOFTWARE FIG 2.1

14
 DIMENSIONS

Fig 2.2
2.3 TRANSFORMATION OF MODEL
Then the model is converted in to the IGES format which is most suitable
and easy access for any other software’s.
Using the IGES format we can import the disc model from SOLIDWORKS
to ANSYS. Now we can make any analysis like structural, thermal analysis etc..,
Geometry imported view of original design disc brake rotor in ansys
workbench Fig 2.3

15
 CHAPTER 3
MATERIAL PROPERTIES
3.1 GRAY 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. Grey cast irons contain appreciable amounts of silicon, normally
1-3%, and consequently these alloys should be considered ternary Fe-C-Si alloys.
graphite is present in the form of flakes. Disc brake discs are commonly
manufactured out of a material called grey cast iron.
Gray iron, or grey cast iron, is a type of cast iron that has a graphitic
microstructure. It is named after the gray color of the fracture it forms, which is
due to the presence of graphite. It is the most common cast iron and the most
widely used cast material based on weight.
Grey cast iron's high thermal conductivity and specific heat capacity are
often exploited to make cast iron cookware and disc brake rotors.
MECHANICAL PROPERTIES

Table 3.1

16
3.2 ALUMINIUM ALLOY
Aluminium alloys typically have an elastic modulus of about 70 GPa, which
is about one-third of the elastic modulus of most kinds of steel and steel alloys.
Therefore, for a given load, a component or unit made of an aluminium alloy will
experience a greater elastic deformation than a steel part of the identical size and
shape. Though there are aluminium alloys with somewhat-higher tensile strengths
than the commonly used kinds of steel, simply replacing a steel part with an
aluminium alloy might lead to problems.

With completely new metal products, the design choices are often governed
by the choice of manufacturing technology. Extrusions are particularly important in
this regard, owing to the ease with which aluminium alloys, particularly the Al–
Mg–Si series, can be extruded to form complex profiles of engine components like
piston.

CHEMICAL COMPOSITION

 Magnesium – 0.65%

 Silicon -0.7 %

MECHANICAL PROPERTIES

Table 3.2

17
3.3CARBON FIBER (HIGH MODULUS)
Carbon fiber, alternatively graphite fiber or CF, is a material consisting of
fibers about 5–10 μm in diameter and composed mostly of carbon atoms. To
produce carbon fiber, the carbon atoms are bonded together in crystals that are
more or less aligned parallel to the long axis of the fiber as the crystal alignment
gives the fiber high strength-to-volume ratio (making it strong for its size). Several
thousand carbon fibers are bundled together to form a tow, which may be used by
itself or woven into a fabric.
MECHANICAL PROPERTIES
Young’s modulus 4.0e+5 MPa
Poisson’s ratio 0.36
Density 6000 kg/m3
Shear modulus 1.4706e+5 MPa
Bulk modulus 4.7619e+5 MPa

Table3.3

ADVANTAGES

The advantages of carbon fibers, such as high stiffness, high tensile strength,
low weight, high chemical resistance, high temperature tolerance and low thermal
expansion.

APPLICATIONS

 Applied in aerospace, civil engineering, military, and motorsports, along

with other competition sports..
 Kite systems use carbon fiber reinforced rods to obtain shapes and
performances previously not possible. High-performance radio-controlled
vehicle and aircraft components such as helicopter rotor blades.

18
 CHAPTER 4
ANSYS

4.1. INTRODUCTION TO ANSYS

ANSYS is an engineering simulation software provider founded by software
engineer John Swanson. It develops general-purpose finite element analysis and
computational fluid dynamics software. While ANSYS has developed a range of
computer-aided engineering (CAE) products, it is perhaps best known for its
ANSYS Mechanical and ANSYS Multiphysics products.
ANSYS Mechanical and ANSYS Multiphysics software are non exportable
analysis tools incorporating pre-processing (geometry creation, meshing), solver
and post-processing modules in a graphical user interface. These are general-
purpose finite element modeling packages for numerically solving mechanical
problems, including static/dynamic structural analysis (both linear and non-linear),
heat transfer and fluid problems, as well as acoustic and electro-magnetic
problems.
ANSYS Mechanical technology incorporates both structural and material
non-linearities. ANSYS Multiphysics software includes solvers for thermal,
structural, CFD, electromagnetic, and acoustics and can sometimes couple these
separate physics together in order to address multidisciplinary applications.
ANSYS software can also be used in civil engineering, electrical engineering,
physics and chemistry.
ANSYS, Inc. acquired the CFX computational fluid dynamics code in 2003
and Fluent, Inc. in 2006. The CFD packages from ANSYS are used for engineering
simulations. In 2008, ANSYS acquired Ansoft Corporation, a leading developer of
high-performance electronic design automation (EDA) software, and added a suite
of products designed to simulate high-performance electronics designs found in
mobile communication and Internet devices, broadband networking components

19
and systems, integrated circuits, printed circuit boards, and electromechanical
systems. The acquisition allowed ANSYS to address the continuing convergence of
the mechanical and electrical worlds across a whole range of industry sectors.

4.2. FINITE ELEMENT ANALYSIS

FEA consists of a computer model of a material or design that is stressed and

analyzed for specific results. It is used in new product design, and existing product
refinement. A company is able to verify a proposed design will be able to perform
to the client's specifications prior to manufacturing or construction. Modifying an
existing product or structure is utilized to qualify the product or structure for a new
service condition. In case of structural failure, FEA may be used to help determine
the design modifications to meet the new condition.

There are generally two types of analysis that are used in industry: 2-D
modeling, and 3-D modeling. While 2-D modeling conserves simplicity and allows
the analysis to be run on a relatively normal computer, it tends to yield less
accurate results. 3-D modeling, however, produces more accurate results while
sacrificing the ability to run on all but the fastest computers effectively. Within
each of these modeling schemes, the programmer can insert numerous algorithms
(functions) which may make the system behave linearly or non-linearly. Linear
systems are far less complex and generally do not take into account plastic
deformation. Non-linear systems do account for plastic deformation, and many
also are capable of testing a material all the way to fracture.

The finite element method is a very important tool for those involved in
engineering design, it is now used routinely to solve problems in the
following areas.
 Structural analysis
 Thermal analysis
20
  Vibrations and Dynamics
 Buckling analysis
 Acoustics
 Fluid flow simulations
 Crash simulations
 Mold flow simulations
Element
Element is an entity, into which a system under study can bedivided
into. An element definition can be specified by nodes. The shape(area,
length, and volume) of the element depends upon the nodes with which it
is made up of.
Nodes
Nodes are the corner points of the element. Nodes are independent entities in
the space. These are similar to points in geometry. By movinga node in space an
element shape can be changed.

0-D Element:
 This has the shape of the point, it requires only one node to define it

1-D Element:
 This has the shape of the line/curve and hence requires minimum of two
nodes to define it.

2-D Element:
 This is an n area element, which has the shape of the quadrilateral/triangle
and hence requires minimum four/three nodes to define it.

21
3-DElements:
This is a volume element, can take the shape of a Hexahedron or a Wedge or
a Tetrahedron. Hexahedron element requires 8 nodes to define its shape. A Pent
element requires 6 nodes to define its shape. Similarly 4 nodes are required to
define a Tetra element. The element is said to be linear or 1storder when it doesn’t
have any mid side nodes. If the mid side nodes are present then those elements are
called Quadratic or 2ndorder elements. For linear elements the edge is defined by a
linear function called shape function whose degree is one. For the elements having
mid side nodes on the edge quadratic function called shape function whose degree
is two is used. The higher order elements when over lapped on geometry can
represent complex shapes very well within few elements. Also the solution
accuracy more with the higher order elements.

4.3. STRUCTURAL ANALYSIS

DEFINITION OF STRUCTURAL 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 the static equivalent wind and seismic loads
commonly defined in many building codes).

LOADS IN A STRUCTURAL ANALYSIS

Static analysis is used to determine the displacements, stresses, strains, and
forces in structures or components caused by loads that do not induce significant
inertia and damping effects. Steady loading and response conditions are assumed;
that is, the loads and the structure's response are assumed to vary slowly with
22
respect to time. The kinds of loading include:

 Externally applied forces and pressures

 Steady-state inertial forces (such as gravity or rotational velocity)
 Imposed (non-zero) displacements
 Temperatures (for thermal strain)

When loads are applied to a body, the body deforms and the effect of loads is
transmitted throughout the body. The external loads induce internal forces and
reactions to render the body into a state of equilibrium. Linear Static analysis
calculates displacements, strains, stresses, and reaction forces under the effect of
applied loads.

Linear static analysis makes the following assumptions:

Static Assumption
All loads are applied slowly and gradually until they reach their full
magnitudes. After reaching their full magnitudes, loads remain constant (time-
invariant). This assumption allows us to neglect inertial and damping forces due to
negligibly small accelerations and velocities. Time-variant loads that induce
considerable inertial and/or damping forces may warrant dynamic analysis.
Dynamic loads change with time and in many cases induces considerable inertial
and damping forces that cannot be neglected.

23
4.4. ANALYSIS PROCEDURE
ANALYZING THE DISC BRAKE – STEP BY STEP PROCEDURE
 The 3D model of the mono disc brake is designed by using pro-e software
and it is converted as IGES format.

 The IGES (Initial Graphic Exchange Specification) format is suitable to

import in the ANSYS Workbench for analyzing

 Open the ANSYS workbench

 Create new geometry

 File – import external geometry file – generate

 Project – new mesh

 Defaults – physical preference – mechanical

 Advanced – relevance center – fine

 Right click the mesh in tree view – generate mesh

 Project – convert to simulation – yes

 Select the all solid in geometry tree

 Definition – material – new material

 New material – right click – rename – gray cast iron

 Enter the value of the young’s modulus, poisons ratio, density and etc.

 New analysis – Static structural

 Static structural – right click – insert – fixed support

 Select the inner circular faces of the disc

24
 Geometry – apply

 Static structural – right click - insert – force – select the face to define the
force direction

 Geometry – apply

 Provide the value of the force to 40286N.

 Static structural – right click - insert – rotational velocity – select the face to
define the direction

 Geometry – apply

 Provide the value of the rotational velocity to 3628.7 rpm.

 Static structural – right click - insert – moment – select the face to define the
direction

 Geometry – apply

 Provide the value of the rotational velocity to 6.043 N-m.

 Then define the solution

 Solution – right click - insert the total deformation, equivalent elastic strain,
and equivalent stress.

 Right click the solution icon in the tree – solve

 Repeat the above steps for aluminium alloy, carbon steel and carbon fiber.

 To capture the figure use the option new figure in tool bar.

 The all results are taken in a picture – and save it to the required folder in the
system. The all readings are tabulated.

25
4.5. PROCEDURE FOR THERMAL ANALYSIS:

 Open ANSYS WORKBENCH

 Create new file. Click steady state Thermal analysis.

 Click geometry - Import new file - XY plane - look at

 Click sketching pick a circle – Draw D1=188mm, D2= 212mm – Generate –

modeling – Extrude – Details of Extrude – operation – Imprint faces –
Generate – Refresh.

 Select model in WORKBENCH window

 Click model - mesh – sizing – relevance center – medium.

 Select model – click one side of disc – symmetry – select other side of disc
– symmetry region.

 Click refresh

 Select steady state thermal – click Heat – click Heat flux – select the hole
wizard – apply – Heat flux magnitude – 33385 w/m2.

 Select convection – select all side of disc – apply – film coefficient –

230 w/m2 0c.

 Select radiation – select all side of disc – apply – ambient temp - 220c.

 Before that we input thermal conductivity values – grey cast iron –

53.3 w/mk – aluminium alloy – 78 w/mk – carbon fiber – (21-180) w/mk.

 Solve - click temperature - total heat flux - generate results.

26
INPUT VALUES APPLIED ON THE DISC BRAKE IN ANSYS
WORKBENCH

fig 4.1

27
 CHAPTER 5
RESULTS
RESULTS FOR EXISTING MATERIAL
5.1. GRAY CAST IRON
TOTAL DEFORMATION

fig 5.1

28
EQUAILENT ELASTIC STRAIN

Fig 5.2

EQUALENT STRESS
Fig 5.3

29
 TEMPERATURE

Fig 5.4
TOTAL HEAT FLUX

Fig 5.5

30
5.2. RESULTS FOR ALUMINIUM ALLOY
TOTAL DEFORMATION

Fig 5.6

31
EQUAILENT ELASTIC STRAIN
Fig 5.7

EQUALENT STRESS

Fig 5.8

32
 TEMPERATURE

Fig 5.9

TOTAL HEAT FLUX

Fig 5.10

33
5.3. RESULTS FOR CARBON FIBER
TOTAL DEFORMATION

Fig 5.11

34
EQUAILENT ELASTIC STRAIN

Fig 5.12

EQUALENT STRESS
Fig 5.13

35
 TEMPERATURE

Fig 5.14
TOTAL HEAT FLUX

Fig 5.15

36
 5.4. COMPARISION OF RESULTS
RESULT FOR EXISTING MATERIAL
GRAY CAST IRON
PROPERTIES MIN MAX
Total deformation (mm) 0 0.1643
Equivalent Elastic Strain (mm/mm) 1.628e-5 9.65e-3
Equivalent stress (MPa) 0.733 1044.7
Temperature (oc) 39.918 76.734
Table 5.1

ALUMINIUM ALLOY
PROPERTIES MIN MAX
Total deformation (mm) 0 0.2637

Equivalent Elastic Strain (mm/mm) 3.331e-5 1.5e-2

Equivalent stress (MPa) 2.059 1028.9

Temperature (oc) 44.45 73.54

Table 5.2

CARBON FIBER
Table 5.3
PROPERTIES MIN MAX
Total deformation (mm) 0 0.04617
Equivalent Elastic Strain (mm/mm) 4.96e-6 2.59e-3
Equivalent stress (MPa) 0.953 1019.1
Temperature (oc) 52.636 68.183

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 CHAPTER-6
CONCLUSIONS

 Analyzing results for disc brake spring under force, moment and rotational

velocity are listed in the Table.

 Analysis has been carried out by gray cast iron (conventional material) and

optimized materials such as aluminium alloy, and carbon fiber. The results

such as total deformation, equivalent elastic strain, equivalent stress,

Temperature and total Heat flux for each material are determined.

 Comparing the optimized materials and the conventional material, carbon

fiber material has the low values of total deformation, stress and strain as

well as in temperature.

 Hence it is concluded that carbon fiber material can be used for disc brake.

 While carrying out this project we are able to study about the 3Dmodelling

software (SOLIDWORKS) and Study about the analyzing software (ansys) to

develop our basic knowledge to know about the industrial design.

38
 REFERENCES

1. http://en.wikipedia.org/wiki/Disc_brake
2. N. Balasubramanyam, Prof. Smt. G. Prasanthi (2014), “Analysis of Disc Brake
Rotor for a Two Wheeler” International Journal of Mechanical and Industrial
Technology.
3. Swapnil R. Abhang, D.P.Bhaskar (2014), “Design and Analysis of Disc Brake”,
International Journal of Engineering Trends and Technology.
4. Manjunath T V and Dr Suresh P M (2013), “Structural and Thermal Analysis of
Rotor Disc of Disc Brake”, International Journal of Innovative Research in
Science, Engineering and Technology
5. V.M.M.Thilak (2012), “Transient Analysis Of Rotor Disc Of Disc Brake Using
Ansys”, IJMIE.

39