Thermal Analysis of Disc brake made of Different Materials

A PROJECT REPORT

Submitted by
PARDUMAN SACHDEVA (RA1711011010068)
RITURAJ DAS (RA1711011010113)

Under the guidance of

Dr. R. Rajendran
(Professor, Department of Automobile engineering)
in partial fulfillment for the award of the degree
of

BACHELOR OF TECHNOLOGY
In

MECHANICAL ENGINEERING
Of

FACULTY OF ENGINEERING AND TECHNOLOGY

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 ABSTRACT

Failure of brakes especially in two-wheelers have been one of the major causes for
many accidents. The forced stresses acting on the disc rotor due to forced braking
damages the disc and eventually it breaks. This shows that no proper material has
been chosen while analysing the disc at different conditions. Thus, the main aim of
this project is to mitigate the failure by using a material which will overcome the
negatives of all the current materials used in a disc brake. Static analysis is done on
the disc rotor to validate the ductility and a thermal analysis is done to determine
the temperature coefficient acting on the disc. Three existing materials that is
Stainless Steel, Cast Iron and Carbon-Carbon Composite is being compared with
Vanadium Steel to check for the maximum deformation, stress and temperature.
The disc brake is modelled using solid-works and the analysis is done in ANSYS
Workbench 15.0. By finishing the analysis, it is proved that Vanadium Steel has
better strength and temperature distribution factors than the other three materials

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 ACKNOWLEDGEMENTS

I would like to express my deepest gratitude to my guide, Dr.R.Rajendran his

valuable guidance, consistent encouragement, personal caring, timely help and
providing me with an excellent atmosphere for doing research. All through the
work, in spite of his busy schedule, he has extended cheerful and cordial support
to me for completing this research work.

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 Table of Contents
ABSTRACT .............................................................................................................. 2
ACKNOWLEDGEMENTS .......................................................................................... 3
INTRODUCTION...................................................................................................... 5
INTRODUCTION TO SOLIDWORKS .......................................................................... 7
INTRODUCTION TO ANSYS WORKBENCH ............................................................... 7
MATERIAL AND METHODS ..................................................................................... 7
• Factors .......................................................................................................... 7
• Selection Process .......................................................................................... 8
• Translation.................................................................................................... 8
• Screening ...................................................................................................... 8
METHODOLOGY USED ........................................................................................... 8
MODEL OF DISC BRAKE .......................................................................................... 9
RESULTS AND DISCUSSIONS OF DISC: .................................................................. 10
• Stainless Steel ............................................................................................. 10
• Cast Iron ..................................................................................................... 11
• Carbon-Carbon Composite ......................................................................... 12
• Vanadium Steel........................................................................................... 13
GRAPH VARIATIONS FOR DIFFERENT CONDITIONS .............................................. 14
CONCLUSION ....................................................................................................... 15
REFERENCE .......................................................................................................... 16

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 INTRODUCTION

As the level of technology of human transportation has increased, the mechanical

devices used to slow down and stop the vehicles has also become more complex.
Before there was horseless carriage, wagons and other vehicles which relied on the
animal’s power for accelerating as well as decelerating the vehicle. Eventually there
was the development of supplemental braking systems consisting of a hand lever
to push a wooden friction pad directly against the metal thread of the wheels. In
wet conditions, these crude brakes would lose any effectiveness. It was in the year
1902 the disc brake was designed in England and incorporated into the Lanchester
car produced between 1906 through 1914. These early disc brakes were not as
effective at stopping as the contemporary drum brakes of that time. After the
World War II, technological progress began to arrive in the 1950s, leading to a
critical demonstration of superiority, a 24 hour of Le Mans race, which required
braking from high speeds several times per lap. Compared to drum brakes, disc
brakes offer better stopping performance because the disc is more readily cooled.
As a consequence, discs are less prone to the brake fade caused when brake
components overheat. Disc brakes also recover more quickly from immersion. A
disc brake works on the principle of Pascal’s Law/Principle of Transmission of fluid
pressure. This law states that “the pressure exerted anywhere in a confined
incompressible fluid is transmitted equally in all directions throughout the fluid
such that the pressure ratio remains same.” Thus the working is very simple. When
the brake lever or pedal is pressed, the push rod which is connected to the lever or
pedal moves and pushes the piston of the cylinder. This movement allows the
master cylinder piston to slide and push the return spring inside the bore of the
cylinder, which generates the pressure in the reservoir tank. Here, a primary seal
allows the brake fluid of reservoir tank to flow over it into the brake hosepipes. A
secondary seal ensures that brake fluid does not go on the other side. Then the
fluid enters into the cylinder bore of caliper assembly via brake hosepipes and
pushes the caliper pistons. Then the caliper piston pushes the brake pad. This
movement causes the brake pads to stick with disc brake which creates friction and
stops the disc rotor to rotate. When the brake lever or pedal is released the piston
ring pushes the caliper piston back to cylinder bore of caliper till both, caliper piston
and piston ring come into their original shape. At this time retraction spring pushes

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the brake pads to their original position. The return spring in master cylinder
assembly pushes the master cylinder piston back into its original position and
allows the fluid to flow back to reservoir via hosepipe and master cylinder bore.
Knowing the failures faced in the disc brake, a deep study was made on the existing
materials and it’s static and thermal analysis during forced braking. In this journal,
a comparison was done on three different materials namely Stainless Steel, Cast
Iron and CarbonCarbon Composite to check the strength and it’s temperature
distribution. This proved that Carbon-Carbon Composite increases the
performance of the disc brake. The main aim of this journal is to increase the
efficiency of the disc rotor by reducing the vibration, cracking, rusting, etc.., using
the existing material. This project covers the important aspects of the brake disc
with the emphasis on material selection methods, structural and thermal analysis,
FEA and optimisation of the disc in order to relate the values.The thermal behaviour
of the ventilated disc brake was analysed using Titanium Alloy (Ti 550) to prove that
Titanium is the suitable material for disc brake. An investigation was done on the
effect of strength variations on the predicted stress distributions by using Cast Iron,
Aluminium Metal Matrix Composite and high strength glass fibre composite
materials. The stress was distributed equally when the disc was made of glass fibre
composite material. Aluminium Metal Matrix Composite material is being used on
the disc in order to check the stress distributions thereby increasing the
performance of the disc brake. In this journal, Carbon Ceramic Matrix is used as the
disc material to calculate the different forces acting on it. Thermal and Modal
Analysis was done to calculate the deflection and heat flux. The author has
examined the deformation and the Von Mises stress established in the disc for both
solid and ventilated disc using two different materials along with thermal analysis
to enhance the performance of the rotor disc. [9] Based on the relationship
obtained between rotor weight,thickness, undercut effect and offset between hat
and friction ring, the criteria for designing the disc rotor has been established in a
vehicle. The final temperature and the total heat flux dissipated by using different
materials like Aluminium Alloy, Cast Iron and Stainless Steel was compared.The rise
in temperature and it’s durability during the time of braking was studied and
analysis is done. The result obtained was used for calculating the rotor rigidity and
maximum temperature rise.

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INTRODUCTION TO SOLIDWORKS
The SOLIDWORKS® CAD software is a mechanical design automation application
that lets designers quickly sketch out ideas, experiment with features and
dimensions, and produce models and detailed drawings.

INTRODUCTION TO ANSYS WORKBENCH

The ANSYS Workbench environment is an intuitive up-front finite element analysis
tool that is used in conjunction with CAD systems and/or Design Modeler. ANSYS
Workbench is a software environment for performing structural, thermal, and
electromagnetic analyses. The class focuses on geometry creation and
optimization, attaching existing geometry, setting up the finite element model,
solving, and reviewing results. The class will describe how to use the code as well
as basic finite element simulation concepts and results interpretation.

MATERIAL AND METHODS

The first step after designing the model of a component is to select the material
with which the model has to be analysed and manufactured. Getting this selection
right the first time by selecting the optimal combination of your design has
enormous benefits to any engineering based business. It leads to lower production
costs, faster time-to-market, a reduction in the number of in-service failures, etc.
But to realise these benefits, engineers have to deal with an extremely complex
problem. There are literally like thousands of materials and no engineer can expect
to know more than a small subset of this ever-growing body of information. So a
detailed study is necessary before selecting a material.
• Factors
When we talk about choosing materials for a component, various factors have to
be taken into account. These factors can be broken down into the following areas.
1. Material Properties
2. Material Cost and Availability

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3. Manufacturing Process
4. Environment

• Selection Process
The material selection process generally involves four basic steps which has to be
analysed before concluding the final material. They are
• Translation
In this step, the design requirements are expressed as constraints and objectives.
Basically, we must first know the function of the component and the work that
component is going to do. In our project, the disc brake is going to withstand tensile
load during braking. Next we must understand the main objective of selecting one
particular material. Here Vanadium Steel has more strength and ductility due to
which the deformation occurred is very small.
• Screening
Screening is the process of eliminating the materials which cannot the prescribed
job. This can be done using material bar charts plotting density in X-axis and Young’s
Modulus in the Yaxis. These two properties are evaluated and analysed. This way
the sub materials are rejected. It is not a problem if there are two or more materials
selected from the list.

METHODOLOGY USED
Initially we decided the domain in which we are planning to work on based on the
interest of the team members. So we finalised on automobiles. When a detailed
study was done on the various aspects of automobiles, we realised that brake plays
a vital role in this field because a considerable amount of accidents have been due
to brake failure. Hence we decided to analyse the disc brakes used in in two-
wheelers. A number of reputed and international journals were studied and we
came to know that brakes also fail due to improper selection of materials. The
brake material should have good ductility in order to withstand forced stresses and
avoid major deformation. Using the material selection process, we researched a
number of materials and it’s properties to decide which material is suitable for the

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disc rotor. This is how Vanadium Steel was selected because it has less density so
the weight of the disc can be reduced considerably and coefficient of friction is less.
The specific heat and thermal conductivity of Vanadium Steel is less when
compared to the current existing materials. After which the disc brake model was
done using solidworks and structural analysis was done using Ansys. Finally the
report was generated where we received a positive result.

PROPERTIES:

MODEL OF DISC BRAKE:

Figure1: Top View of Disc

The two-dimensional solid with shape and dimensions is created in solidworks. The
disc diameter is 266mm and the thickness of the disc is 3mm.
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RESULTS AND DISCUSSIONS OF DISC:
• Stainless Steel
Then the result of Total deformation, Normal Stress, Normal Elastic Strain of
Stainless Steel after analysis 15.0.

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 • Cast Iron
Then the result of Total deformation, Normal Stress, Normal Elastic Strain of Cast
Iron after analysis 15.0.

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 • Carbon-Carbon Composite
Then the result of Total deformation, Normal Stress, Normal Elastic Strain of
Carbon-Carbon Composite after analysis 15.0.

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 • Vanadium Steel
Then the result of Total deformation, Normal Stress, Normal Elastic Strain of
Vanadium Steel after analysis 15.0.

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 Structural Analysis of Disc Brake

GRAPH VARIATIONS FOR DIFFERENT CONDITIONS:

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 Normal Strain of Disc Brake using different materials

CONCLUSION
Thus the structural analysis was done on the Disc Brake by comparing Stainless
Steel, Cast Iron and Carbon-Carbon Composite with Vanadium Steel. The analysis
has proved that Vanadium Steel has better strength than other materials as it can
withstand forced stresses thereby showing that the deformation occurring on the
disc rotor will be minimum. The values obtained from the structural analysis is less
than the prescribed values. Hence the design of the Disc Brake Rotor is safe.

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REFERENCE

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