Title: Thermal Analysis Of Disc Brakes

Submitted by:
Arooj Kanwal
Muhammad Arif
Muhammad Afaq

Submitted to:
Sir Khubaib Haider

FEA Open Ended Lab Report

Abstract:
This study presents a comprehensive thermal analysis of disc brakes employed in the Nissan
Sentra and racing cars. The investigation focuses on crucial parameters such as total deformation
and equivalent stress to assess the structural performance under varying thermal loads. The
Nissan Sentra disc brake exhibited a total deformation of 0.0001345 meters and an equivalent
stress of 5.3005 x 10^8 Pa, showcasing robust performance under braking conditions. In contrast,
the racing cars' disc brake displayed a slightly higher total deformation of 0.00014036 meters
and a greater equivalent stress of 6.0124 x 10^8 Pa. The results underscore the Nissan Sentra
disc brake's superior thermal stability, making it an effective choice for mainstream automotive
applications, while the racing cars' disc brake, optimized for specific performance metrics, may
excel in racing scenarios where specialized characteristics take precedence.

Introduction:
Disc brakes are a crucial component in modern automotive braking systems, providing efficient
stopping power for vehicles. Unlike traditional drum brakes, disc brakes consist of a flat, rotating
disc attached to the wheel. When the brake pedal is pressed, brake calipers squeeze brake pads
against the disc, creating friction and converting kinetic energy into heat. This process slows
down and eventually halts the vehicle.
Disc brakes offer advantages such as better heat dissipation, consistent performance in various
conditions, and reduced braking distances. They are widely used in cars, motorcycles, bicycles,
and other applications where reliable and responsive braking is essential. The design and
materials of disc brakes continue to evolve, aiming to enhance durability, reduce weight, and
improve overall braking efficiency.
Disc brakes are widely used in cars, trucks, motorcycles, bicycles, and other vehicles due to their
reliability, efficiency, and superior braking capabilities, especially in high-performance and
heavy-duty applications.
Problem Statement:
The problem is to compare the thermal performance of two different models of disc brakes. This
involves analyzing how well each disc brake handles heat generated during braking. The
objective is to understand which model dissipates heat more effectively, as excessive heat can
affect braking performance and safety. The thermal analysis will help determine the brakes'
ability to maintain optimal functioning temperatures, ensuring reliable and safe operation under
various conditions.
Ni
s sa
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Sentara Disc Racing

Car Disc

Disc Brake:
The brake disc is like the spinning part of a car's brake system, and it's where the brake pads
press to slow down the car. Usually, it's made of gray iron, a strong type of cast iron. Now, some
discs are solid, like a thick plate, while others have spaces in the middle or fins connecting the
two sides. The choice depends on how heavy the vehicle is.
If a car is heavy or powerful, it might need what we call "ventilated" discs. These discs have
openings or fins, and this design helps to cool them down when they get hot from braking a lot.
Ventilated discs are often used on the front wheels, especially if they do a lot of heavy lifting in
terms of stopping the car.
Now, if you look at discs on motorcycles, bicycles, or even some cars, you might notice holes or
slots in them. This isn't just for looks – it's to let heat escape better, disperse water on the surface,
make less noise, lighten the disc, or sometimes just because it looks cool and sporty. So, whether
it's a solid disc or one with holes, the brake disc is a crucial part of how your brakes work and
stay cool.

Terminologies and Definitions:

Here are some key terminologies associated with disc brakes along with their definitions:
Disc Brake: A type of braking system that utilizes calipers to squeeze brake pads against a
rotating disc (rotor) attached to the wheel, creating friction and slowing down or stopping the
vehicle.
Caliper: A device containing pistons and brake pads that, when activated, presses the brake pads
against the disc to generate friction and initiate the braking process.
Brake Pads: Friction material attached to the caliper that makes contact with the disc when the
brakes are applied, creating the necessary friction to slow down or stop the vehicle.
Rotor: The disc-shaped component attached to the wheel hub, against which the brake pads are
pressed to generate friction and facilitate braking.
Ventilated Disc: A type of brake disc design with openings, fins, or vanes that allow air to pass
through, enhancing heat dissipation during braking. Commonly used in high-performance or
heavy-duty applications.
Heat Dissipation: The process of dispersing the heat generated during braking to prevent the
brake components from overheating, ensuring consistent and effective braking performance.
Brake Fade: A reduction in braking efficiency caused by the overheating of brake components,
leading to diminished stopping power. Ventilated discs are designed to minimize brake fade.
Slotting and Drilling: Techniques involving the addition of slots or holes to the disc surface to
improve heat dissipation, reduce noise, and enhance the overall performance and aesthetics of
the disc.
ABS (Anti-lock Braking System): An advanced safety system that prevents wheel lock-up
during braking, maintaining steering control and vehicle stability, especially in emergency
braking situations.
Hydraulic Brake System: A braking system that uses hydraulic fluid to transmit the force
applied on the brake pedal to the brake calipers, resulting in the activation of the brake pads
against the disc.

Advantages of Disc Brakes:

1. Disc brakes are better at dissipating heat generated during braking, reducing the risk of
brake fade and maintaining consistent performance.
2. Disc brakes offer rapid response times, providing immediate braking power when
needed, contributing to enhanced safety and control.
3. Compared to drum brakes, disc brakes generally require less maintenance. They are more
accessible for inspection and replacement, leading to lower upkeep costs.
4. Disc brakes are more compact and lightweight than drum brakes, contributing to overall
vehicle weight reduction and improved fuel efficiency.
 5. Disc brakes are less prone to water buildup, making them more effective in wet
conditions compared to drum brakes, which may experience reduced performance when
wet.
6. The open design of disc brakes allows for better airflow, aiding in cooling and preventing
overheating during heavy braking, particularly in high-performance or heavy-duty
applications.

Limitations of Disc Brakes:

1. Disc brakes are generally more expensive to manufacture and replace than drum brakes,
contributing to higher initial vehicle costs and potentially increased repair expenses.
2. Disc brake components, especially rotors, can be prone to corrosion, which may affect
their longevity and performance, particularly in regions with harsh weather conditions.
3. Disc brake systems are more complex than drum brakes, involving additional
components such as calipers and rotors. This complexity can lead to higher repair and
maintenance costs.
4. Disc brakes may produce more noise during operation, such as squealing or grinding
sounds, which can be a nuisance for some drivers.
5. Disc brakes generate brake dust as they wear, which can accumulate on wheels and other
components, affecting aesthetics and requiring additional cleaning.
6. Integrating a parking brake into a disc brake system can be more challenging compared to
drum brakes, making repairs or adjustments potentially more involved.

Solid Work Models of Disc Brake:

Model:1
Model: 2

Geometrical construction:
Solid work was used for the design purpose of the model. This file was then converted from
SLDPRT” file to that of “. iges” file due to the reason that ANSYS does not support the
“SLDPRT” file.

Now import the geometry in ANSYS software.

Meshing:

Temperature:

Convection:
Solution:

Rotational velocity:
Fixed Support:

Pressure 1:
Pressure 2:

Static Structural:
Total Deformation:

Equivalent Stress:
2nd model Mesh:

Temperature and Convection:

Solution:
Static Structural:

Total Deformation:
Equivalent Stress:

Comparsion:
Total Deformation:
Equivalent stress:

Nissan Sentra Disc Brake

Total Deformation 0.0001345m

Equivalent Stress 5.3005x10^8 pa

Racing Cars Disc Brake

Total Deformation 0.00014036m

Equivalent Stress 6.0124x10^8 pa

The analysis and design of disc brakes for both the Nissan Sentra and racing cars were
thoroughly investigated in this report. The key parameters considered for evaluation were the
total deformation and equivalent stress, providing insights into the structural performance and
mechanical behavior of the disc brakes under specific conditions.

Nissan Sentra Disc Brake:

Total Deformation: The calculated total deformation for the Nissan Sentra disc brake was found
to be 0.0001345 meters. This parameter indicates the amount of deformation or displacement
experienced by the brake disc under the applied load. A lower total deformation suggests that the
disc brake retains its structural integrity and shape more effectively during braking conditions.
Equivalent Stress: The equivalent stress for the Nissan Sentra disc brake was determined to be
5.3005 x 10^8 Pascals. Equivalent stress is a crucial factor in assessing the material's ability to
withstand the applied load without undergoing plastic deformation. A lower equivalent stress
signifies better resistance to mechanical failure.

Racing Cars Disc Brake:

Total Deformation: The total deformation for the racing cars' disc brake was slightly higher at
0.00014036 meters compared to the Nissan Sentra. While still a small value, it indicates a
slightly greater amount of deformation under the same load conditions. This could be a result of
the performance-oriented design of racing car components, which may prioritize factors other
than minimal deformation.
Equivalent Stress: The equivalent stress for the racing cars' disc brake was calculated to be
6.0124 x 10^8 Pa. This value is higher than that of the Nissan Sentra disc brake, suggesting that
the racing car disc brake is subjected to a more significant stress level during operation. This
may be intentional in racing car design to prioritize other factors like weight reduction or
enhanced heat dissipation.

Results:
the Nissan Sentra disc brake exhibited a total deformation of 0.0001345 meters and an equivalent
stress of 5.3005 x 10^8 Pa. In comparison, the racing cars' disc brake showed a slightly higher
total deformation of 0.00014036 meters and a greater equivalent stress of 6.0124 x 10^8 Pa.
While both disc brakes meet structural integrity standards, the Nissan Sentra disc brake
demonstrates marginally superior performance with lower deformation and stress levels. The
Nissan Sentra disc brake is widely used in mainstream automotive applications, benefiting from
its effective balance between performance and durability. However, the racing cars' disc brake,
optimized for specific performance criteria, may be more effective in racing scenarios where
other factors like weight reduction and heat dissipation take precedence. Ultimately, the choice
between the two depends on the intended application, with the Nissan Sentra disc brake being the
preferred option for widespread automotive use.