OPTIMIZATION AND ANALYSIS OF
VENTED DISC BRAKE
MITHILESH S1, KOTTE V KARTHIK PAWAN KUMAR2, MOHIT BANSAL3, ZUBAIR AHMAD TANTRAY4,
VARUN SAI KURAKULA5, DR. MANPREET SINGH6
1,2,3,4,5
DEPARTMENT OF MECHANICAL ENGINEERING, 6PROFESSOR, DEPARTMENT OF MECHANICAL
ENGINEERING, LOVELY PROFESSIONAL UNIVERSITY, KAPURTHALA, PUNJAB, INDIA
Abstract— This paper uses finite element
analysis to optimize a disc brake's efficiency
under different braking conditions. Braking is
a mechanism that transforms a vehicle’s
kinetic energy into mechanical energy, which
must be dissipated as heat. Brakes convert
friction to heat, but if they get too hot, they
will stop working due to inadequate heat
dissipation. To assess and compare their
output, a static thermal analysis was performed
on the disc rotor, and the temperature
distribution was analyzed using cooling
parameters. It has been proposed that the
results of finite element simulation and good
material be used.
Keywords: Thermal analysis, Ventilated disc
brake, Heat Transfer coefficient, Heat flux.
I. INTRODUCTION
There are two types of disc brakes: solid
complete and ventilated. disc brake is a
mechanism that slows or stops a wheel's
rotation. The wheel and/or axle are connected
by a disc brake, which is typically made of
cast iron or ceramic composites (including
carbon, Kevlar, and silica). Friction material
in the form of brake pads (mounted on a
system called a brake caliper) is pushed
against both sides of the disc mechanically,
hydraulically, pneumatically, or
electromagnetically to stop the wheel. These
brakes have better stopping efficiency than
comparable drum brakes, as well as
resistance to "brake fade," which is caused by
brake components overheating. They may
also easily re-cover after being submerged.
Friction brakes well as the applied actuation
pressure, determine the stopping power or
potential of a friction brake. Wear occurs on
the brake's working surfaces, and the type of
friction material used on the brake's
replaceable surfaces determine how long it
can last. Heat transfer is low when a disc
brake is used in a solid structure. operate by
producing frictional forces between two or
more surfaces. The area in contact and
coefficient of friction of the working
surfaces, as Cooling the disc takes a short
time. Since the area of contact between the
Rotor and the Pads is greater when the brake
disc is in a solid body, the brake's
performance is higher. They must stop the
vehicle in the shortest period of time possible
by transforming the vehicle's kinetic energy
into heat energy, which is then dissipated into
the atmosphere. The following are the
primary criteria for braking: The brakes must
be powerful enough to stop the vehicle in the
shortest amount of time possible in an
emergency. During emergency braking, the
driver must maintain careful control of the
vehicle and the vehicle must not skid. The
disc brake assembly is made up of three
parts: a spinning rotor, a caliper assembly
connected to the steering knuckle, and disc
pads fixed to the caliper assembly.
The disc brake is a type of wheel brake that
slows wheel rotation by causing friction by
pressing brake pads against a brake disc with
calipers. The brake disc is usually made of
cast iron, although composites such as
reinforced carbon–carbon or ceramic matrix
composites can be used in some cases. This is
connected to the axle and/or the wheel.
Friction slows or stops the disc and its
attached wheel. Brakes convert motion into
heat, and when they get too hot, they lose
their effectiveness, which is known as brake
fade
TYPES OF BRAKE DISC
Flat Brake Disc
The basic brake disc is a flat, smooth disc
affixed to the rotating axle spindle, usually
made of iron. Many cars, particularly smaller
cars, come fitted with these because their
lighter weight makes them suitable for the job
and they are relatively inexpensive to
manufacture and repair. Because of the wide
surface area in contact with the pad, they have
excellent braking strength, but they can lose
effectiveness over time. Heat, gas, and waste
friction material may build up between the disc
and the pad, causing fading and possibly
warping if the heat builds up to dangerous
levels.
Vented Brake Disc
The load on the brakes rises in proportion to
the vehicle's size and weight. This creates more
heat, which causes brake system problems.
Braking systems convert kinetic energy (speed)
into heat through friction between the brake
pad and disc. As the temperature rises, the disc
requires assistance in venting the heat quickly
enough to avoid damage. One of the primary
reasons disc brakes are superior to drum brakes
is that they are exposed, while drum brakes
suffer from visible brake fade due to
ineffective ventilation. A vented design, which
looks like two discs sandwiched with spokes
between them, is required to assist the disc in
dissipating excess heat. This makes it easier for
the heat produced by the contact surfaces to
escape by radiating out the back and through
the vents between the two sides. The only
disadvantage of a vented disc is a small rise in
weight; otherwise, they are much better than
regular flat discs at remaining within optimum
working temperature limits.
Drilled Brake Disc
Another technique for keeping discs cool is to
maximize their surface area by drilling holes
all the way into them. These holes also allow
heat, gas, and waste material to escape,
preventing them from accumulating on the
contact surfaces. The drilled-out material also
helps to lighten the weight of the discs. Drilled
discs have certain drawbacks. The holes can
accumulate material and other debris, and
they're also vulnerable to warping and cracking
when exposed to high temperatures. The holes
do not threaten the disc's structural integrity,
but they do limit the amount of heat it can
withstand until it reaches the amount it can
effectively dissipate.
Slotted or Grooved Brake Disc
Adding slots or grooves to a disc functions
similarly to drilling discs in that it removes
excess heat, gas, and material from the friction
surface while preserving the disc's heat
resistance. The groves radiate outward at a
specific angle from the disc's core, venting
waste out and away as the disc rotates. Since
the grooves scrub the pads, these discs are
noisier than others. Brake Disk with Slots and
Drills in Combination A disc with a mix of
slots and holes is a typical solution that aims to
get the best of both worlds while minimizing
the drawbacks. The number of holes is reduced
to keep heat resistance high while still allowing
waste to be channeled away, and the number of
slots is reduced to minimize noise while still
allowing pads to be scrubbed and renewed.
Dimpled Brake Disc
The primary goal of dimpling is to lose weight
while maintaining strength and resistance. The
venting capabilities, especially of heat, are
reduced by not having a hole all the way
through to the disc interior. The dimples also  Young’s modulus (E) = 125 GPa
cause friction material to escape before being  Poisson’s ratio (v) =0.25
blown away from the friction surface.

Material Properties
Stainless Steel
Material Cast iron Stainless
properties steel Stainless steel is a term that refers to a diverse
Thermal co- 9.9*106/0C 6*10-6/0C group of engineering materials that are chosen
efficient of primarily for their corrosion and heat resistance
expansion properties. At this stage, chromium reacts with
(Kxx) oxygen and moisture in the atmosphere to
Thermal 54.0 W / m k 40 W /m k create an oxide film that covers the entire
conductivity surface of the material and is adherent and
(K) coherent. This oxide film (also known as the
boundary layer or passive layer) is extremely
Specific heat 586.0 j / kg k 460J / Kg K thin [1 nanometer = 10-9 m]. When the passive
(cp) layer on stainless steels is weakened, the
chromium in the steel reacts quickly with
Convection 100 W / m2k 50 W / m2k oxygen and moisture in the atmosphere to
film co- reform the oxide layer, which is a truly
efficient remarkable property. Stainless steel is a term
that refers to a diverse group of engineering
Ambient 250C 250C materials that are chosen primarily for their
temperature corrosion and heat resistance properties. At this
(ta) stage, chromium reacts with oxygen and
moisture in the atmosphere to create an oxide
Density 7100kg/ m3 7800Kg/ m3 film that covers the entire surface of the
material and is adherent and coherent. This
oxide film (also known as the boundary layer
or passive layer) is extremely thin [1
Cast Iron nanometer = 10-9 m]. When the passive layer
Cast iron is most often associated with grey on stainless steels is weakened, the chromium
cast iron, but it also refers to a wide group of in the steel reacts quickly with oxygen and
ferrous alloys that solidify with a eutectic. The moisture in the atmosphere to reform the oxide
major alloying elements are carbon and silicon, layer, which is a truly remarkable property.
with iron accounting for more than 95% of the For stainless-steel,
total. Young’s modulus = 200 GPa
Cast iron has a carbon content of 2.1-4 percent, Poisson’s ratio = 0.3
with ferrous alloys containing less being
referred to as carbon steel by definition. Since
cast irons contain large amounts of silicon,
usually 1-3 percent, these alloys should be
categorized as ternary Fe-C-Si alloys. Graphite
flakes are present in this region. Grey cast iron
is the most common material used to produce
disc brake discs. for cast iron,