DISC BRAKE ANALYSIS

MECHANICS OF MATERIALS-I LAB REPORT

REPORT ON THE DESIGN AND ANALYSIS OF AUTOMOTIVE CAR DISC BRAKES

BY: SHAHZAIB JAHANGIR 2015-ME-75

MUHAMMAD ALI 2015-ME-76

MUHAMMAD SARMAD SHAZAD 2015-ME-77

SAAD IDREES 2015-ME-78

MECHANICS OF MATERIALS LAB CAR DISC BRAKES

AERODYNAMIC COOLING OF DISC BRAKES

Friction (mechanical) brakes are the most widespread and used disc brakes in operation by the
automotive industry despite the recent developments in the field of car automation but they bring
their own merits and demerits along, the first being their cooling properties.

NEED FOR COOLING

The rotation of the automotive wheel is comprised of the potential and kinetic energies that have
been supplied to it via the engine and once the disc brakes are applied these energies are
converted into thermal (heat) energy at the interface of the disc and the braking pads significantly
heating and raising the temperature of the brakes. It is therefore vital that sufficient cooling
mechanism is implemented for the successful operation of the disc brakes and to avoid pre-
mature wear and tear.

Several types of failures may arise if the disc brakes are not sufficiently and timely cooled. These
may include:

BRAKE FADE
Brake fade is said to arise when due to elevated temperatures the brake disc fail to serve their
purpose and braking returns once the temperature of the disc brake falls below the critical level.
As a result of high temperatures, the coefficient of friction between the disc and the braking pads
reduces resulting in decreased braking capacity and finally brake failure.

BRAKE FLUID VAPORIZATION

If the temperature of the braking mechanism increases as much as the boiling temperature of the
braking fluid, it may cause the lubricant to vaporize in the hydraulic mechanism producing a gas
vapor state due to which the force applied may only compress the vapor formed and not actuate
the brakes leading to failure.

EXCESSIVE COMPONENENT WEAR

All materials are temperature dependent in terms of their strength, hardness and mechanical /
physical properties. With insufficient cooling the thermal expansion and breakage of the
surrounding components such as the rotor plate may occur giving rise to pre-mature wear and
tear of these parts.

The wearing of one movable part introduces malfunction in its neighboring parts leading to an
overall disruption and distortion in the mechanical systems.

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MECHANICS OF MATERIALS LAB CAR DISC BRAKES

DISSIPATION OF HEAT
Once a braking operation is launched the braking disc temperature depends on a number of
factors including the mass of the vehicle, the rate of deceleration and the duration for which the
brakes have been applied. If the braking has been done for a short span, then the heat generated
will not be considerable as no noticeable effects are produced and the heat generated will soon
be dissipated.

In ideal cases, the heat generated at the rotor pad interface is readily dissipated into the
atmosphere by which no heat rise takes place but in most real cases the rate of heat dissipated
is often lower compared to the heat generated as a result of constant braking. Since heat
generation is larger than dissipation thus heat and consequently temperature of the disc brakes
rises sharply which will ultimately lead to failure.

Heat conduction to the atmosphere takes place along the rotor, the pads and the clamping units.
Further dissipation of heat occurs through convection currents but researches have unveiled that
heat transfer through conduction and convection in normal conditions accounts for only two
percent. Similarly, although radiation specially at higher temperatures allows for the most
dissipation but still it only transfers less than five percent of the total energy transferred.

PRIMARY MEANS OF HEAT TRANSFER: CONVECTION

As a result, it is agreed upon that the primary and most effective source of heat dissipation from
disc brakes into the atmosphere is through convection.

Convection is undertaken by the expression 2.1.1

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MECHANICS OF MATERIALS LAB CAR DISC BRAKES

Now it is clear from the expression that in order to increase the heat transfer it is required that
either the heat transfer coefficient h or the surface area of the rotor is increased. It is evident that
since the surface area of the rotor is limited by its diameter therefore it is viable to use a material
such whose heat transfer coefficient h is ideal.

The use of an internally ventilated rotor will increase both surface area (extra internal area
exposed to the atmosphere) and the heat transfer coefficient, due to forced convection
created by the internal airflow design. The greater the volume of contact of air is with the disc
brakes the greater will be the rate of heat transfer and thus cooling. For this purpose, an extensive
aerodynamic study is performed for various disc brakes according to the geometry and shape of
the disc brakes.

MATERIAL SELECTION FOR DISC BRAKES

Material selection plays a vital role in fuel consumption and removal of Noise, vibration, harshness
(NVH). Many economic parameters are also to be determined. Generally, Material selection
contains two methods.

Cost Per unit property

Digital Logic method

To reduce automobile weight and improve fuel efficiency, the auto industry has used many
materials for brake disks. They include Cast iron, Aluminum alloys, Titanium alloys, Ceramics and
composites. Many mechanical properties are also to be considered for the purpose of material
selection. These include

Compressive strength
Friction coefficient
Wear resistance
Thermal conductivity
Specific gravity

Preferable Materials for Brake disks:

As mentioned above, many materials can be used for hardness, ductility and reliability for
manufacturing of car braking systems. But according to properties of friction generation and
ability to perform efficient braking following materials can be used.

I. CAST IRON:
Generally cast irons are the class of ferrous alloys that generally contain quantity of
carbon ranging from 3 to 4.6 wt. %. They have low melting points as compared to steel,
which is 1150C to 1300C, so they are suitable for casting processes.

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MECHANICS OF MATERIALS LAB CAR DISC BRAKES

Cast irons can be classified into following types:

Gray iron
Ductile (nodular) iron
White iron
Malleable iron
Compacted graphite iron

i) Grey Cast Iron:

Grey cast iron contains contents of silicon and carbon ranging from 1 to 3 wt.% of Si and
2.5 to 4 wt.% of Carbon. Also, it contains graphite in form of flakes. Many desirable properties
are contained by grey iron. Due to graphite flakes, grey color appears on its surface as per its
name. They have many mechanical properties that they have high brittleness and low
ductility. High strengths make it prominent and hence are used extensively for production
of mechanical tools such as engine casings and car brakes.

ii) Ductile Iron:

Ductile iron contains a small amount of magnesium to the grey cast iron. With this
addition, it becomes more ductile and less brittle. But under constant stresses, permanent
deformation can take place.

iii) White Iron:

Have small value of Silicon (Less than 1%) and rapid cooling rates. With fast cooling during
casting generate, high brittleness and hardness even more than grey iron. So, it is hard to
machine them. However hard wears of machines for examples rollers and cutting tools are
generated by them. They are not preferred for brakes because of hard machining properties
that makes them more prominent.

iv) Malleable Iron:

These are special types of white cast irons that are generated by heating white iron at
elevated temperatures. They offer better ductility than white or grey cast irons. But mostly
cannot be used to manufacture car disk brakes.

v) Compacted Graphite Iron:

A relatively recent addition to the family of cast irons that have many superior properties
than other family members. Carbon exists as graphite and silicon components are also
present there ranging from 1.7% to 3%. They have a wormlike structure that makes them
special. they contain many properties that are

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MECHANICS OF MATERIALS LAB CAR DISC BRAKES

Higher thermal conductivity

Better resistance to thermal shock
Lower oxidation at elevated temperatures
These properties make them useful for production of brakes and hence brakes can be
generated using them.

ADVANTAGES OF CAST IRON:

Cast irons are used extensively for production of disks of brakes at higher levels. Many
advantages of them are given below

Grey cast iron has high brittleness and good resistance to continuous vibrational
effects. They can bear shear as well as normal stresses. So, they are preferred for
production.
Honda, Toyota, Suzuki, Nisan, BMW, Renault, Skoda And TATA motors use grey cast
iron and copper alloy to manufacture disk of brakes because these alloys offer
resistance to heat, hardness and better performance under action of continuous
stresses.
Compacted Graphite iron do not show oxidation even at elevated temperatures so
they are safe as material. During application of brakes, temperature is elevated so no
reaction must take place. System must remain isolated.
Cast iron brakes are economical, so their production is simple as just casting and
other machining processes are required. They are applied in cars that have a
moderate speed range.
It is economical as compared to steel and other alloys. So, because of this reason,
many manufacturing industries prefer it for manufacturing of disk brakes.

Figs: A view of cast iron disc brakes (Pictures taken at local workshop)

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MECHANICS OF MATERIALS LAB CAR DISC BRAKES

DISADVANTAGES OF CAST IRON:

It is heavier and contains high value of weight that can be harmful for many
operations.
It cant be used directly some amount of silicon is to be added in it.
Machining is required for its manufacturing as after casting it cannot be used directly.

II) Aluminum:
Aluminum and its alloys are generally classified by relatively low density compared
to cast iron and steel. It has a lighter weight that makes it prominent for usage for many
mechanical operations. But for car Disc brakes it cannot be used practically, especially for
high speed automotive. Its advantages and disadvantages are given below.

Figs: A view of cast iron disc brakes (Pictures taken at local workshop)

ADVANTAGES:
Generally, Aluminum is lighter in weight that makes it very important.
They possess high resistance to corrosion.
They provide low temperature toughness properties.
So, Al is preferred for making bodies of air craft and jets.

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MECHANICS OF MATERIALS LAB CAR DISC BRAKES

DISADVANTAGES:
For manufacturing of car disk brakes Aluminum is not practical. It has many disadvantages
that are mentioned below.

Aluminum has low melting point (660oC). This temperature can be obtained during
braking operation for high speeding cars. So, it cannot be used for that.
In alloy form, resistance to corrosion tends to decrease so it may harm our disk.
It is too costly, so that economically it is very hard to use it.
It can be deforming by cold working so during application of brakes, it may deform.
It is a strong conductor of heat and electricity, but in case of disk brakes we do not want
our heat to be conducted thought our system.

III) TITANIUM ALLOYS:

Titanium and its alloys are relatively new engineering materials that possess extraordinary
combination of properties. The pure metal has a relatively low density a high melting point.

Figs: A titanium alloy often used in cars today.

Some advantages are given below

ADVANTAGES:
They have a high melting point (1668oC) that is very high as compared to Aluminum. So,
for braking operations they are suitable because of elevated temperature abilities.
Titanium alloys are extremely strong; at room temperature, tensile strengths are as high
as 1400Mpa that make it perfect for making car disk brakes.
They offer remarkable specific strengths. Also, alloys are highly ductile and easily Forged
and machined.

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MECHANICS OF MATERIALS LAB CAR DISC BRAKES

DISADVANTAGES:
They offer difficulty in casting to make disk because of their relatively high melting point.
They are chemically reactive so cant be used because during braking operations,
temperature is increased and they may react with air or some other gas in air.
They are relatively expensive and costly to handle.
They are generally used in making of alloy rims. But for car brake discs they are not
preferred

IV) MAGNESIUM AND ITS ALLOYS:

Magnesium is another significant material with lighter properties as aluminum. So, they have also
lighter properties but cannot be used for making disks of brakes because of low melting point of
magnesium (651oC) so it cannot be used. It is used for production of car bodies not disks brakes

Figs: Use of magnesium alloys in cars.

V) COPPER AND ITS ALLOYS:

Copper also possess desirable combinations of many properties that make is useful in
many useful operations. Their advantages and disadvantages are given below.

ADVANTAGES:
It is highly resistant to corrosion.
Have high tensile strengths as 1400Mpa that is very prominent in mechanical operations.
They may be cast, machined, Forged or cold worked easily.

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MECHANICS OF MATERIALS LAB CAR DISC BRAKES

DISADVANTAGES:
Have a high cost and thus uneconomical.
Is soft and for disks they cannot be used.
Bronze and Brass alloys are useful but are expensive.
Have high thermal conductivities like copper so cannot be used practically for production
of disk brakes. But for low speeding bodies like cycle and motorbike, they can be used in
form of alloys.

Fig: Copper alloy brake shoe (PAD).

VI) SUPER ALLOYS:

The super alloys have superlative combinations of properties. Most are used in air crafts,
turbines components, which must withstand exposure to severely oxidizing environment and
high temperatures for reasonable time periods. They are generated by group of metals as Iron,
Nickel, and cobalt. But they are too expensive and cannot be used for disks.

Some other materials can also be considered but they are precious and too expensive like
platinum, Noble metals and Zirconium but we cant be used for production of brakes.

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MECHANICS OF MATERIALS LAB CAR DISC BRAKES

VII) NON-METALLIC MATERIALS

CERAMICS:
In modern technology, new materials are introduced in many operations. Ceramics are
compound between metallic and nonmetallic elements. They are most frequently oxides, nitrides
and carbides. For example, common ceramic materials include aluminum oxides or alumina,
silicon dioxide, silicon carbide, silicon nitride and in addition to many other materials are added
in ceramics. In many modern materials, they offer a lot of contributions.

Figs: Ceramic disc plates with perforations for ventilation.

ADVANTAGES:
Some advantages of ceramics are given below

They are heat resistant and resist heat during braking applications.
They are hard and offer good hardness, and reliability.
They are manufactured by heat treatment processes and are easy to tackle.
Modern Ceramic materials can be used to manufacture engine parts in automotive
industry.
Their properties can be enhanced by using some other alloys as silicon dioxide.
ABS brakes are preferred to generate by using them.
Have lighter weight.
Ceramics are melted at high temperature that (183C) which is useful in disk
manufacturing.

DISADVANTAGES:
They are costly and are preferred for high speeding cars and air craft brakes.
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MECHANICS OF MATERIALS LAB CAR DISC BRAKES

WOOD:
Generally, in production of car disk brakes we want, high frictional values to control the speed
of our cars, this can be done by using wood instead of other materials mentioned above, But In
case of woody brakes hard wood must be used, so that it may not tear during braking operations,
by making the surface rough and compatible we can produce a hard brake disc that would be
lighter in weight and provide more value of friction,

But the only challenge we have to face is that after some time (like 2 to 3 years) Even hardest
wood on this planet would be deformed or have to face some dislocations in structure, and there
is a big possibility of firing

Another huge challenge is that wood can be burnt, but in spite of many precautions it would face
semi cracks that may cause breakage of disc and can provide a big chance of accident.

Figs: A view of wooden disc brakes rarely in use.

OUR PREFERENCE
Taking all factors into account, our group prefers to employ CERAMIC MATRIX COMPOSITE disks
because of several reasons:

High melting point makes them superior over cast iron.

They are heat resistant and are suitable for brakes.
Last about 60 times larger than cast iron.
Si combined with C-Fiber and makes it more compatible.
They are lighter, harder and reliable in hotness of dessert, cold of glaciers, and humidity
of coastal areas that make them perfect for any of the situation of production of brakes.
Hydraulic system is introduced with it to generate a better grip over wheel.

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MECHANICS OF MATERIALS LAB CAR DISC BRAKES

STRESS ANALYSIS

THERMAL STRESS:
The rotational and translational kinetic energy of the disc brakes converts majorly into heat and
sound energy once the disc brakes are applied. As a result the temperature of the disc brakes
rises sharply giving rise to unavoidable wear and tear of pads and accompanying components. All
those effects will cause noise and vibration during braking, lowering value of friction coefficient
and forward reducing brakes efficacy, and further on, traffic safety. Thermal stress is a result of
exterior constrains during temperature variation T inside the brake disc, having no possibility to
expand or constrict. It can be expressed as

During braking the heat is generated by the friction between disc and pads and is dissipated by
convection and radiation.

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MECHANICS OF MATERIALS LAB CAR DISC BRAKES

MATHEMATICAL RELATION OF THERMAL STRESS:

The surfaces of disc which remains in contact with pads will have higher values of temperature,
which can cause, in time, thermal stress inside the brake disc. The stresses are amplified in some
cases by the pressure between pads and disc. While pads press the disc during braking, the heat
generated will cause both of them to expand. If Poisson coefficient is considered negligible then

The total accumulated heat flux Q is obtained by dividing the brake power by swept area of the
disc brake,

Q(t)=kma(V1-at)/S1 Where S1 is swept area of the disc brake by brake pads.

Where Q(t) is time varying heat flux.

The stress from the S1 area can be written as:

Where p=p(max)*r2/r

Where p(max) is maximum pressure distributed on pad.

And p is radial pressure on the disk brake.

is friction co-efficient which varies with temperature for different materials.

A part of the heat flux Q is dissipated by radiation and given by;

Where A is the area of the disk radiation heat.

And is the Boltzmann constant.

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MECHANICS OF MATERIALS LAB CAR DISC BRAKES

The time variation of stress can also be written as follows;

From two values of temperature T1 and T2 of disk brake, obtained from two values of
radial speed 1 and 2 , thermal stress ratio can be written as follows:

VON MISES STRESS ANALYSIS:

Von Mises stress is widely used by designers to check whether their design will
withstand a given load condition. If the Von Mises stress for a material exceeds the
yield strength for a given material, then the product fails and disrupts. The same theory
can be applied to car disc brakes which would fail to function if the stress exceeds their
tensile strength.

The left-hand side of the above equation is denoted as Von Mises stress.

The material will fail if the Von Mises stress (calculated as shown above) exceeds the
yield strength of the material.

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MECHANICS OF MATERIALS LAB CAR DISC BRAKES

Another general way to calculate the normal stresses acting on disc brakes can be
given by
Work done by disc brakes in t sec is given as= Ft * * d* N* t
and E = F t * * d* N* t
then Ft = E/*d*N*t
Since force is related to stress by F=*A

= E/*d*N*t*A
then

where is shear stress and A is the area

DEPENDENCE OF DISK BRAKES DESIGN:

In short, we can summarize that the following factors determine the design of car
disc brakes:

The pressure on unit surface are between the contacting surfaces of the
brakes.
Coefficient of friction of surfaces.
The outer boundary velocity (or peripheral velocity) of the drum brake.
Projected area of friction surfaces.
The quality of brake material to endure the energy absorbed during braking.
Expected yield stress to be applied.
Means of ventilation and cooling.

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MECHANICS OF MATERIALS LAB CAR DISC BRAKES

GALLERY

The group visited a local car repair workshop where a few pictures of the disc brakes were taken
and practical examination was done.

Fig: Braking system of car from front.

Fig: Disc plate of a Suzuki Mehran car.

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