IJSTE - International Journal of Science Technology & Engineering | Volume 3 | Issue 07 | January 2017

ISSN (online): 2349-784X

Finite Element Modeling for Linear Analysis of

Disc Brake
Mohammed Akram Junaid Shareef
B. Tech. Student B. Tech. Student
Department of Mechanical Engineering Department of Mechanical Engineering
Lords Institute of Engineering and Technology Hyderabad Lords Institute of Engineering and Technology Hyderabad
India India

Md Azher Jaffer Mohammed Asif

B. Tech. Student Assistant Professor
Department of Mechanical Engineering Department of Mechanical Engineering
Lords Institute of Engineering and Technology Hyderabad Lords Institute of Engineering and Technology Hyderabad
India India

Mohammed Iqbal
Assistant Professor
Department of Mechanical Engineering
Lords Institute of Engineering and Technology Hyderabad India

Abstract
The Finite element method in general and commercial finite element analysis software in particular implemented in a computer
offers a unified approach for engineering analysis. The focus in this report is on the Linear structural analysis of a disc brake
made of Grey Cast Iron and Aluminum material using ANSYS software. The disc is subjected to centrifugal loading by angular
velocity and pressure loading by a caliper radically. The significant result for Gray Cast Iron and Aluminum are present and
found aluminum has low stress and it has best performance. Finally the report concludes with identification of topics for future
works.
Keywords: Disc Brake, CATIA, ANSYS APDL, Structural Analysis, and FEM Analysis
________________________________________________________________________________________________________

I. INTRODUCTION

Disc Brake
A disk brake consists of a cast iron disk 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 as is cast in two parts each part containing a piston. In between each
piston and the disk 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.

Fig. 1: Assembly of Disc Brake

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 Finite Element Modeling for Linear Analysis of Disc Brake
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A hydraulically disc brake comprises one or two opposing pistons each faced with a pad of lining material. When the
hydraulic pressure is increased the pads are forced against the rotating metal friction disc, exerting a normal force at each
contact. The two normal forces cancel one another axially but cause additive tangential friction forces & retard the motion of the
vehicle.

II. DESIGN OF A DISC BRAKE

Disc Brake
For the proposed design of disc brake parameters considered are pressure and angular velocity for different material.
Pressure calculation for a disc brake used for a three wheeler car is shown below.
Considerations
Load distribution considered for vehicle is 40:60 from centre of gravity.
Average Pedal effort applied by a common man 15kg.
Maximum Speed of vehicle is assumed to be 50kmph.
The calculations are same for both front and rear wheel brakes, up to the brake line after master cylinder.
Estimated speed of the vehicle = 50Kmph
Estimated pedal effort of the driver=15Kgs =147.15N
Mechanical advantage or pedal ratio=4:1
Force acting on master cylinder = (Estimated pedal effort of the driver*4)=147.15*4=588.6N
Diameter of master cylinder=0.75 =19.05mm
Area of master cylinder=285 mm2
Pressure acting on master cylinder = (force*area) = 588.6*285= 2.065N/mm2
The maximum pressure distribution for a disc brake obtained as 2.065Mpa.
The disc brake selected for analysis is of Bajaj Pulsar 150. Dimensions of the model are mention in figure 2.

Modeling of Disc Brake in CATIA

Fig. 2: Dimensions of Disc Brake

Fig. 3: Modeling of disc Brake in CATIA

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 Finite Element Modeling for Linear Analysis of Disc Brake
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The above shown Fig.3 is model drawn in the CATIA software by using the dimensions of the Pulsar 150 disc brake with
correct thickness and Dimensions.

III. FINITE ELEMENT MODEL OF A DISC BRAKE

Geometric Model
Geometric model of a disc brake created in CATIA is imported in ANSYS APDL as show in fig 4.

Fig. 4: Geometric Model of Disc Brake

Table - 1
Material Properties of Grey Cast Iron & aluminum
Property Grey Cast Iron Aluminium
Density (Kg/m3) 7200 2690
Youngs Modulus (G pa) 110 68.9
Poissons Ratio 0.28 0.36
Thermal Conductivity (w/m-k) 533 210
Specific Heat (J/kg-k) 506 900

Meshed Model and Boundary Conditions

Discretized model of a disc brake is shown in figure 5.
Element type: Solid 186
Number of elements: 1505

Fig. 5: Discretized model of a disc brake

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 Finite Element Modeling for Linear Analysis of Disc Brake
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Fig. 6: Boundary Condition

All degrees of freedom for an inner boundary of a disc are fixed. Radial centrifugal force is applied by angular velocity =
1104.5 rpm and a Radial pressure of 2.06 Mpa is applied as shown in figure 6.

IV. RESULT ANALYSIS OF A DISC BRAKE

Significant result obtained for disc brake made of Grey Cast Iron & Aluminum is shown in table 2 below.
Table - 2
Results of Grey Cast Iron & aluminum
Analysis Materials
Grey Cast Iron Aluminium
Minimum Maximum Minimum Maximum
Displacement(mm) 0 3.93223 0 1.63635
Stress (Mpa) 16437.3 22906.6 4622.03 6637.47
Von mises stress (Mpa) 177.609 36740.5 65.2206 9626.07

Stress Analysis of a Grey Cast Iron

The fig. 7 shown below is the displacement diagram of the Grey Cast Iron obtained in the stress analysis performed. It can
withstand maximum displacement 3.93223 mm. The fig. 8 shown below is the stress diagram of the Grey Cast Iron obtained in
the stress analysis. It can withstand maximum stress 22906.6 Mpa which is performed in ANSYS APDL Software.

Fig. 7: Displacement

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 Finite Element Modeling for Linear Analysis of Disc Brake
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Fig. 8: Stress

The fig. 9 shown below is the von mises stress diagram of the Grey Cast Iron obtained in the stress analysis. It can withstand
maximum von mises stress is 36740.5 Mpa which is performed in ANSYS APDL Software.

Fig. 9: Von mises stress

Stress Analysis of Aluminum

The fig. 10 shown below is the displacement diagram of the aluminum obtained in the stress analysis. It can withstand maximum
displacement of 1.63635 mm. The fig. 11 shown below is the stress diagram of the aluminum obtained in the stress analysis. It
can withstand maximum stress 6637.47 Mpa which is performed in ANSYS APDL Software

Fig. 10: Displacement

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 Finite Element Modeling for Linear Analysis of Disc Brake
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Fig. 11: Stress

The fig. 12 shown below is the von mises stress diagram of the Aluminum obtained in the stress analysis performed in
ANSYS APDL Software. It can withstand a maximum von mises stress of 9626.07 Mpa.

Fig. 12: Von mises Stress

V. CONCLUSION

The identified problem is so complex that analytical solutions are not possible. Experimental investigation an prohibitively
expensive however finite element modeling using ANSYS Software is demonstrated to provide accurate numerical over a wide
range of parameters involved the graphical post processing capabilities exploited to display the results and animate displacement
of disc. The significant result of the disc brake is safe based on the strength and rigidity criteria. By comparing the above results
obtained from the structural and stress analysis, we can conclude that aluminum has low stress and it has best performance.

VI. FUTURE WORK

The identified problem can further analyze for contact non-linearity, thermal analysis for same or different materials. The
significant results can be validated by experimentally.

REFERENCES
[1] Praveena S, Lava Kumar M, SreeKanth Reddy s. Modeling and Structural Analysis of Disc Brake, International Journal of Innovative Research in
Science, Engineering and Technology. vol. 3, Issue 10, October 2014
[2] Manjunath T V, Dr Suresh P M.Structural and Thermal Analysis of Rotor Disc of Disc Brake, International Journal of Innovative Research in Science,
Engineering and Technology. vol. 2, Issue 12, December 2013
[3] Kamana.VishnuVardhanChowdary, D.V.S.R.B.M Subhramanyam.Design and Analysis of Disc Brake, International Journal of Professional Engineering
Studies. vol. V, Issue 5, October 2015

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 Finite Element Modeling for Linear Analysis of Disc Brake
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[4] Er. N. B. Shinde, Prof. B.R.Borkar.C.A.D and F.E.M Analysis of Disc Brake System, International Journal of Engineering and Computer Science.vol. 4,
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[5] Dr.Kripal Singh, Automobile Engineering vol. 1
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[9] ANSYS 14.5 Manual, CATIAV5-6.
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