Babu, et al, International Journal of Advanced Engineering Research and Studies

E-ISSN22498974

Research Paper

STRUCTURAL DESIGN AND THERMAL ANALYSIS OF CAR

DISC BRAKE ROTOR
K. Naresh Babu 1, T.Siva Krishna2

Address for Correspondence

M. Tech Student, 2Assistant Professor, Department of Mechanical Engineering, QIS College of Engineering &
Technology, Ongole 523272, Andhra Pradesh, India
ABSTRACT
The motive of undertaking this project of Structural Design and Thermal Analysis of Car Disc Brake Rotor is to study and
evaluate the performance under severe braking conditions and there by assist in disc rotor design and analysis. This study is
of disc brake used for cars.
ANSYS is a finite element package used for determining the temperature distributions, variation of stresses and
deformations across the disc brake profile.
In this present work, an attempt has been made to investigate the effect of stiffness, strength and variations in disc brake
rotor design on the predicted stress and temperature distributions. By identifying the true design features, the extended
service life and long term stability is assured. This paper studies about the model of a disc brake used in Toyota Rav4. A
transient thermal analysis has been carried out to investigate the temperature variation across the disc using axis-symmetric
elements. Further structural analysis is also carried out by coupling thermal analysis.
An attempt is also made to suggest a best combination of materials (like Cast iron, stainless steel, High strength S-glass fiber
and Aluminum metal matrix composite), flange width and wall thickness used for disc brake rotor, which yields a low
temperature variation across the rotor, less deformation, and minimum von-misses stress possible.

1.0 INTRODUCTION
A disc brake consists of a disc component 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 hydraulic
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 following figure.

Figure .3: Location of Disc Brakes in a car

2.0 DISC BRAKE ROTOR MODEL DESIGN

Figure 1: Disc Brake full assemble view

1.1 Working Principle

When the brakes are applied, hydraulically actuated
pistons move the friction pads in to contact with the
disc, applying equal and opposite forces on the later.
On releasing the brakes the brakes the rubber-sealing
ring acts as a return spring and retract the pistons and
the friction pads away from the disc (see fig).

Figure .2: Working principle of Disc brakes

Int. J. Adv. Engg. Res. Studies/III/I/Oct.-Dec.,2013/45-51

Figure .4: Solid Disc Brake Rotor isometric view

3.0 THERMAL STRUCTURAL ANALYSIS
Temperature distributions in different materials
In transient thermal analysis a time varying thermal
load (temperature load) is applied and its behavior is
analyzed. Both convection and heat flux parameters
are considered for evaluation of results. Although the
convection coefficient varies with velocity and
surface a general convection coefficient of 5
W/(m2.C) is taken for both internal and external
convection. In this case study, a time varying
temperature load is calculated for a car of mass
1400Kg travelling at 31.11 m/s brought to a complete
stop (one complete stop).
Thermal Loads:
Heat flux (q) = 881141.3283 W/ m2 (for 4 seconds of
braking)
Heat flux (q) =704913.0626 W/m2 (for 5 seconds of
braking)

Babu, et al, International Journal of Advanced Engineering Research and Studies

Heat flux (q) =587427.5522 W/m2 (for 6 seconds of

braking)
Convection film co-efficient (h) = 5.0 W/ m2 k

E-ISSN22498974

Temperature fixed at the hub bore grinds = 35C

Case 1: At flange thickness of 10 mm

Figure .5: Temperature distribution in steel Disc at 6 sec of breaking time (for 10 mm thick flange)

Figure .6: Temperature distribution in AMMC Disc at 6 sec of breaking time (for 10 mm thick flange)

Case 2: At flange thickness of 12 mm

Figure .7: Temperature distribution in S2-glass Disc at 6 sec of breaking time (for 12 mm thick flange)

Figure .8: Temperature distribution in AMMC Disc at 4 sec of breaking time (for 12 mm thick flange)

Int. J. Adv. Engg. Res. Studies/III/I/Oct.-Dec.,2013/45-51

Babu, et al, International Journal of Advanced Engineering Research and Studies

E-ISSN22498974

Case 3: At flange thickness of 15 mm

Figure .9: Temperature distribution in cast iron Disc at 6 sec of breaking time (for 15 mm thick flange)

Figure .10: Temperature distribution in AMMC Disc at 6 sec of breaking time (for 15 mm thick flange)

4.0 Comparison of Temperature distributions in Disc materials

Figure .11: Formation of vonmises stresses in S2-glass at 6sec of breaking time (for 10 mm thick flange)

Int. J. Adv. Engg. Res. Studies/III/I/Oct.-Dec.,2013/45-51

Babu, et al, International Journal of Advanced Engineering Research and Studies

E-ISSN22498974

Figure .12: Formation of vonmises stresses in S2-glass at 6sec of breaking time (for 12 mm thick flange)

Figure .13: Formation of vonmises stresses in S2-glass at 6sec of breaking time (for 15 mm thick flange)

Figure .14: Formation of Vonmises stresses in Cast iron disc at 6sec of breaking (for 10 mm thick flange)

Figure .15: Formation of Vonmises stresses in Castiron disc at 6sec of breaking (for 12 mm thick flange)

Int. J. Adv. Engg. Res. Studies/III/I/Oct.-Dec.,2013/45-51

Babu, et al, International Journal of Advanced Engineering Research and Studies

E-ISSN22498974

Figure .16: Formation of Vonmises stresses in Castiron disc at 6sec of breaking (for 15 mm thick flange)

Figure .17: Formation of Vonmises stresses in Steel disc at 6sec of breaking (for 10 mm thick flange)

Figure .18: Formation of Vonmises stresses in Steel disc at 6sec of breaking (for 12 mm thick flange)

Figure .19: Formation of Vonmises stresses in Steel disc at 6sec of breaking (for 15 mm thick flange)

Int. J. Adv. Engg. Res. Studies/III/I/Oct.-Dec.,2013/45-51

Babu, et al, International Journal of Advanced Engineering Research and Studies

E-ISSN22498974

Figure .20: Formation of Vonmises stresses in AMMC disc at 6sec of breaking (for 10 mm thick flange)

Figure .21: Formation of Principal stresses1 in AMMC disc at 6sec of breaking (for 12 mm thick flange)

Figure .22: Formation of Vonmises stresses in AMMC disc at 6sec of breaking (for 15 mm thick flange)

5.0 Comparison of Thermal stresses in Disc Brake

Rotor
Now for establishing a best material for the car disc
brake rotor for the present application, four different
materials which are commonly used for the disc
brakes namely Cast Iron (CI), stainless steel 302
annealed (S.S), Aluminium metal matrix composite

(AMMC), high strength S2-glass fiber were taken

and analysis is done using their properties on the disc
brake rotor with 6.5mm wall thickness with different
flange widths at 4, 5 and 6 seconds of breaking time.
Case1: The following table illustrates the Thermal
stresses distribution in Disc Brake Rotor for 10 mm
thick flange at 4, 5 and 6 seconds of braking time

Table .1: Comparison of Thermal stresses distribution in disc rotor for 10 mm thick flange

Case2: The following table illustrates the thermal stresses distribution in Disc Brake Rotor for 12 mm thick
flange at 4, 5 and 6 seconds of braking time.
Int. J. Adv. Engg. Res. Studies/III/I/Oct.-Dec.,2013/45-51

Babu, et al, International Journal of Advanced Engineering Research and Studies

E-ISSN22498974

Table .2: Comparison of Thermal stresses distribution in disc rotor for 12 mm thick flange

Case3: The following table illustrates the thermal stresses distribution in Disc Brake Rotor for 15 mm thick
flange at 4, 5 and 6 seconds of braking time.
Table .3: Comparison of Thermal stresses distribution in disc rotor for 15 mm thick flange

6.0 CONCLUSIONS
The following conclusions are drawn from the
present work.
An Axis-symmetric analysis of disc brake
has been carried out using elements Plane
55 and Plane 42 through ANSYS 12.0
(F.E.A) software.
A transient thermal analysis is carried out
using the direct time integration technique
for the application of braking force due to
friction for time duration of 4, 5 and 6
seconds.
The maximum temperature obtained in S2Glass brake disc at the contact surface is
observed to be 125.3 C.
Static structural analysis is carried out by
coupling the Thermal solution to the
structural analysis and the maximum
Vonmises stress in S2-Glass brake disc is
observed to be 60.3 M Pa.
The Brake disc design is safe based on the
Strength and Rigidity Criteria.
To arrive at a best combination of
parameters of the Disc Brake like Flange
width, wall thickness and Material Transient
Thermal and Structural Analysis for three
different combinations in each of the four
different materials were carried out
separately and the results were compared.
Comparing the different results obtained
from the analysis, it is concluded that disc
brake with 12 mm flange width, 6.5 mm
Wall Thickness and of material high
strength S2-Glass is the Best possible
combination for the present application.
REFERENCES
1.
2.
3.
4.
5.
6.
7.
8.

Introduction to Finite Elements in Engineering by

Chandrupatla &Belegundu
A.C.Delco Disc Rotors Catalogue book
User Guide for ANSYS 12.0
Internet web site WWW. How Stuff works.com
A Text book of Machine Design by Pandya & Shaw.
A Text book of Machine Design by R.S. Khurmi &
J.K.Gupta
Machine Design Data hand Book by PSG college of
technology
Heat and Mass Transfer Data Book by C P
Kothandaraman, S Subramanyan

Int. J. Adv. Engg. Res. Studies/III/I/Oct.-Dec.,2013/45-51