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Design and Analysis of Disc Brake Rotor

Conference Paper March 2015

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 International Journal of Applied Engineering Research ISSN 0973-4562 Volume 10, Number 19 (2015)
Research India Publications ::: http://www.ripublication.com

Design and Analysis of Disc Brake Rotor

Venkatramanan R*, Kumaragurubaran SB*, Vishnu Kumar C*, Sivakumar S#,

Saravanan B$.
*
P.G students&#Asst.Prof, Department of Mechanical Engineering
RVS College of Engineering,Coimbatore, Tamilnadu,India
$
Assistant Professor, Department of Automobile Enigineering, Karpagam College of Engineering,
Coimbatore, Tamilnadu, India

Abstract :A brake is a mechanical device which slowing or stopping a moving object or

preventing its motion. This work deals with the thermal analysis of disc brake of a
vehicle. Heat generation and dissipation of disc brake are analysed. The objective of this
work is to investigate and analyze the temperature distribution of rotor disc during
operation using Ansys. The standard disc brake two wheelers model using in Ansys and
done the Thermal analysis and also calculate the Heat flux, Temperature of disc brake
model. This is to understand the pressure force and friction force on the disc brake
material,which can help to reduce the accident that may happen in each day. In this
research work design of a disc brake is proposed with copper liner on its brake disc, the
heat transfer of existing and hybrid disc will be calculated for finding the effectiveness of
heat transfer.

analysis approached has been conducted in

1 Introduction
The most important part of a vehicle
is Brake system. Brakes are required to stop
the vehicle within the possible distance and it
is done by converting kinetic energy of the
vehicle into heat energy by friction which is
dissipated into atmosphere. The brakes are
strong enough to stop the vehicle within the
least possible distance. Brakes should also be
consistent with safety. The driver should have
a good control over the vehicle during panic
braking. During the panic brake the vehicle
should not skid. The brakes should have
proper antifade characteristics and their
effectiveness should not decrease with
application. A disc brake assembly consists of
Disc rotor that rotates with the wheel, Calliper
assembly attached to the steering knuckle,
disc pads that are mounted to the calliper
assembly.
This work shows a heat generation
and dissipation of a disc brake of a vehicle
during emergency braking and the following
release period.Brakes which slows the vehicle
and thus transforms kinetic energy into heat
energy which results in heating of the brake
disc. If the disc overheats the brake pads
which fades and it can melt in rare cases.Zaid,
et al. (2009) a presented paper on
investigation of disc brake by Finite element
analysis. In this paper, the author has
conducted a study on ventilated disc brake
rotor of vehicle. This study is concern with
heat and temperature distribution on disc
brake rotor. In this paper, finite element
order to identify the temperature distributions
of disc brake rotor. ANSYS has been used as
finite elements software to perform the
thermal analysis of disc brake. This study
provide us an understanding on the thermal
characteristic of disc brake rotor and assist the
automotive industry in developing optimum
and effective disc brake rotor.
Manjunath and Suresh[1]presented a
paper to study the analysis of thermo-
mechanical behaviour of the brake disc during
the braking. The thermal-structural analysis of
disc brake is used to determine the
deformation and the Von Mises stress in the
disc for solid and ventilated disc with two
different materials to investigate the
performance of the rotor disc. A comparison
between theoretical and analytical results are
obtained from finite element model is done.
The obtained values from the analysis which
are less than their allowable values. Hence the
suitable design and material of rotor disc is
suggested and based on the performance,
strength and rigidity.
N. Balasubramanyam[2] a transient
analysis for the thermo-elastic contact
problem of the disk brakes with heat
generation is performed using the finite
element analysis. To analyse the thermos-
elastic phenomenon occurring in the disk
brakes, heat conduction and elastic equations
are solved. The numerical simulation for the
thermo-elastic behaviour of disk brake is
obtained in the repeated brake condition. The
analytical results are presented for the

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Research India Publications ::: http://www.ripublication.com

distribution of heat flux and temperature on transfer (conduction, convection and

each friction surface between the contacting radiation) have been analyzed. The results
bodies. obtained from the analysis shows that
Pratik P[3]Numerical methods and different material on the same retardation of
analysis procedures used in the study of the car during panic braking shows different
automotive disc brake. It covers Finite temperature distribution.
Element Method approaches in the automotive Thus, a comparison is made between
industry. This review can help analysts to different material used for brake disc and the
choose right methods and make decisions on best material for making brake disc based on
new areas of methoddevelopment. The the rate of heat dissipation have been
complex Eigen value method is choose for suggested.
contact analysis of car disc brake. The essence
of such a method lies inthe asymmetric 2.PROCEDURE
stiffness matrix derived from the contact
stiffness and the friction coefficient at the disc Design Specification
interfaces. This paper presentsthe analysis of of rotor
the contact pressure distributions at the disc
interfaces using a detailed 3-dimensional
finite element model of a real cardisc brake. It Modelling
is also investigates different levels in
modelling a disc brake system and simulating
contact pressure distributions atvarying load. Meshing
BouchetaraM[4],The main purpose of
this study is to analyse the thermos-
mechanical behaviour of the dry contact Tangential Force
between the brake disc and pads during the between Pad and Rotor
braking phase. The simulation is based on
computer code ANSYS. The modelling Brake Torque
oftransient temperature in the disc is actually Calculation
used to identify the factor of geometric design
of the disc to install theventilation system in Braking Distance
vehicles. The thermo-structural analysis is Calculation
then used with coupling to determine the
deformationestablished and the Von Mises
stresses in the disc, the contact pressure in Heat Generated
Through Braking
brake pads.
Swapnil R BhaskarD.P[5],In this
paper carbon ceramic matrix disc brake Fig2.1 : Flow chart of Design and Analysis
material use for calculating piston force,
normal force andshear force. And also 2.1. DESIGN SPECIFICATION OF
calculating the brake distance of discbrake. ROTOR
The disc brake two wheelers model using Rotor disc dimension 240 mm
inANSYS and done the Thermal analysis and
Modal analysis alsocalculate the Heat flux, Rotor disc material ASTM G50 Grey
Temperature distribution of disc brakemodel. Cast Iron
This work is to understand action force and Pad brake area 0.0067 m2
frictionforce on the disc brake. Pad brake material Asbestos
HarshdeepShergill[6]This work deals Coefficient of friction 0.07-0.13
with the analysis of heat generation and (Wet)
dissipation in a disc brake of an car during Coefficient of friction 0.3-0.5
panic braking and the following release period (Dry)
by using computer aided engineering software Maximum temperature 350 C
for three different materials of rotor disc. The Maximum pressure 1MPa (10e6 Pa)
objective of this work is toanalyze the
temperature distribution of rotor disc during
operation using COMSOL. The work uses the
finite element analysis techniques to predict 2.2 MODELLING OF DISC ROTOR
the temperature distribution on the brake disc
and to identify the critical temperature of the Modeling of disc brake is generated using
brake rotor disc. All three modes of heat SOLID WORKS. The model of brake disc asa

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 International Journal of Applied Engineering Research ISSN 0973-4562 Volume 10, Number 19 (2015)
Research India Publications ::: http://www.ripublication.com

3D. The disc has a radius of 0.120 m and a

thickness of 0.050 m
2.4TANGENTIAL FORCE BETWEEN
PAD AND ROTOR (INNER FACE)
FTRI = Normal force between pad brake and
Rotor (Inner)

1 =Coefficient of friction = 0.5

A =Pad brake area

-Eq.(1)
-Eq.(2)
So,
Fig.2.2 :3D Drawing of disc rotor with
copper liner
FTRI = 0.5 x 0.5 x 1e6 x 0.0067
2.3MESHING =1675 N

Meshing is for converting a whole Tangential force between pad and rotor FTRO
objectinto finite no. of parts known as which is equal to FTRI because of same
discretization. Meshing of thebrake disc and normal force and same material.
pad has been done using ANSYS. The
element used for meshing is of 2.5BRAKE TORQUE (TB)
tetrahedralshape.
Assumption of equal coefficients of friction
and normal forces on the faces:

-Eq.(3)

Where, TB = Brake torque

is the coefficient of friction, FT is the total

normal forces on disc brake (inner and outer
face) = 1675 N and R is the radius of rotor
disc.
TB = (1675) (12010e-3)
= 201 Nm

2.6 Brake Distance

We know that tangential braking force acting
at the point of contact of the brake, and

-Eq.(4)

[Fig. 2.3.1: Meshed Model of Disk Rotor] Where FT is the total normal forces on disc
brake and x is the distance travelled (in meter)
Table 2.3.2Material properties of disc rotor and by the vehicle before it come to rest.
brake pad We know kinetic energy of the vehicle.
Material Grey cast
Asbestos
Properties iron -Eq.(5)
Density 7200 2000
Thermal
Where m is the mass of vehicle and v is the
conductivity 50 8.7
velocity of vehicle
Heat capacity
460 935 In order to stop the vehicle to, the work done
against friction must be equal to kinetic
Emissivity 0.44 0.80 energy of the vehicle.

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 International Journal of Applied Engineering Research ISSN 0973-4562 Volume 10, Number 19 (2015)
Research India Publications ::: http://www.ripublication.com

temperature distribution is helpful to plot

Comparing Eq. (4) and (5) temperature. We can see that the maximum
temperature is approximately 603.5 C. The hot
spot is positioned close to the radially outer
edge of the pad. The highest temperature
occur approximately 5 s after engaging the
Assuming, brake.
v = 100 km/h =27.77 m/s and
m =132 kg. (Dry weight of Vehicle)
So, we get

x =(13227.772) / (21675)
=30.38 m

2.7 HEAT GENERATED THROUGH

BRAKING
Heat Generated in disc rotor (J/s)

-Eq.(6)
Fig 3.1 Temperature Distribution without
Heat Flux (W/m2) Copper Liner

The temperature distribution for grey cast iron

which shows as 603.5c while using copper
Where, mass of disc is 0.848 kg, specific heat liner in the disc brake the temperature in the
capacity of disc is 490 J/kg K, time taken brake disc rotor is reduced to 335.98c.
stopping the vehicle is 5sec, developed
temperature difference (T) is 15 C and area
of disc is 0.06328 m2

Q = 0.848 * 490 * 15= 6232 J

-Eq.(7)

Heat flux = (6232 /5) / 0.03828 =32560 W/m2

Fig. 3.2 Temperature Distribution with

-Eq.(8)
Thermal gradient =32560/ 40=814 K/m
Analyse of the work are:
(i) How the temperature generated during
braking?
(ii) How much the heat dissipated during the
subsequent rest?
3. FEA RESULT OF DISC BRAKE
The result of the disc brake has been
analyzed and compared with and without
copper liner in the disc rotor. The position of
Copper Liner
CONCLUSION
On the basis of the current work, it is
concluded that the copper liner which
dissipates the heat as grey cast iron. The cast
iron has the maximum temperature produced
is about 603.5c without copper liner. The cast
iron has the maximum temperature produced
is about 335.98c with the presence of copper
liner. So from above we can conclude that
copper liner can be used in brake disc which
will give moderate cooling at low temperature
as compare to grey cast iron.So it can be used
in racing cars where high temperature will
produced.

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 International Journal of Applied Engineering Research ISSN 0973-4562 Volume 10, Number 19 (2015)
Research India Publications ::: http://www.ripublication.com

REFERENCE

[1] M. T. V and D. S. P. M, "Structural and

Thermal Analysis of Rotor Disc of Disc
Brake," International Journal of
Innovative Research in Science,
Engineering and Technology, vol. 2,
no. 12, pp. 7741-7749, 2013.

[2] B. N and P. G, "Design and Analysis of

Disc Brake Rotor for a Two wheeler,"
International Journal of Mechanical
and Industrial Technology, vol. 1, no.
1, pp. 7-12, 2014.

[3] P. P. C. D. S. B. Jaju, "A REVIEW ON

THERMAL AND CONTACT STRESS
ANALYSIS OF DISC BRAKING SYTEM,"
International Journal of Engineering
Research and General Science, vol. 2,
no. 1, pp. 78-84, 2014.

[4] B. M. Belhocine A, "Temperature and

Thermal Stresses of Vehicles Gray
Cast Brake," Journal of Applied
Research and Technology, vol. 11, pp.
675-682, 2013.

[5] D. Swapnil R. Abhang, "Design and

Analysis of Disc Brake," International
Journal of Engineering Trends and
Technology, vol. 8, pp. 165-, 2014.

[6] H. S. Haripal Singh, "Thermal Analysis

of Disc Brake Using Comsol,"
International Journal on Emerging
Technologies, vol. 3, no. 1, pp. 84-88,
2012.

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