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ENGINEERING COLLEGE BIKANER

(A Constituent College of Bikaner Technical University, Bikaner)

A
Final Year project progress report (Stage-1)
On
DESIGN OPTIMIZATION OF DISC BRAKE BY USING
FINITE ELEMENT ANALYSIS

Students Supervisor
Sahil Shakay Dr. O.P. Jakhar
(21EEBME012) Dr. Vineet Kumar
Jatin Dabi
(21EEBME007)
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Table of Contents
Abstract ................................................................................................................................ 3
Chapter 1: Introduction ......................................................................................................... 4
1.1 Introduction to disk brake ............................................................................................. 4
1.2 Parts of the disc brake ................................................................................................... 5
1.2.1 Brake Pads ............................................................................................................. 5
1.1.2 Rotor ...................................................................................................................... 6
1.1.3 Support and Caliper ............................................................................................... 6
1.1.4 Brake fluid ............................................................................................................. 7
1.1.5 Fluid reservoir ........................................................................................................ 7
1.3 WORKING PRINCIPLE OF DISC BRAKE .................................................................. 7
1.4 TYPES OF DISC BREAK ............................................................................................. 8
1.4.2. Twin piston ............................................................................................................ 8
1.4.3. Twin Caliper.......................................................................................................... 8
1.4.4. Ventilated Discs ..................................................................................................... 9
1.5. The benefits and drawbacks of disc brakes .................................................................... 9
1.5.1. Disc brakes have the following benefits: .................................................................. 9
1.5.2. drawbacks of disc braking: ............................................................................... 9
Chapter 2 ............................................................................................................................ 10
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Abstract

A disc brake system in automobiles performs three important functions: reducing the
speed of the vehicle, maintaining speed while going downhill, and completely stopping
the vehicle. During braking, the disc brake can face problems like stress, structural
deformation, and wear and tear of the pads. This project studies the temperature of the
disc, stress concentration, structural deformation, and the contact pressure between the
disc and pads during a single braking event using ANSYS software.

The analysis focuses on frictional forces, nodal displacement, and buckling under
different pressure conditions. Based on this, the most suitable material for the disc brake
will be identified to ensure better durability and longer life. Preliminary analysis shows
that one material improves braking efficiency and gives more stability. Additionally, a
comparison of different materials will be done to find the best option for better
performance and longer life.
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Chapter 1: Introduction

1.1 Introduction to disk brake

A brake system is intended to reduce and stop a vehicle's motion. This is accomplished by the
brake system's numerous components turning the vehicle's motion energy into heat. The fact
that is carried out by use of friction. The force that two things apply to one another to prevent
movement is called friction. Two types of friction—static or stationary and kinetic or moving—
are involved in vehicle control. A material's friction or resistance to movement is determined
by its kind, the smoothness of its rubbing surfaces, and the pressure holding it together.
One kind of brake that is utilized in the brake system is the disc brake.
In the 1890s, disc-type brake development got underway in England. Although the disc was
thin and the brake pad was triggered by a cable, the Lanchester Motor Company's 1902 brake
design appeared and functioned similarly like a contemporary disc-brake system. It took
another 60 years for alternative car designs to become commercially available or feasible.
Aircraft were the first to successfully use it prior to World War II.
Although the disc cools more easily than a drum brake, disc brakes provide superior stopping
power. Discs are therefore less vulnerable to brake fade, which is brought on by overheating
braking components. Additionally, disc brakes bounce back from submersion faster.A servo-
effect is produced by the majority of drum brake designs having at least one leading shoe. In
contrast, the braking force of a disc brake is always proportionate to the pressure applied to
the brake pad by the braking system through any brake servo, braking pedal, or lever. This
helps the driver avoid an oncoming lockup and tends to give them a better feel. In addition,
drums are vulnerable to bell mouthing and trap worn lining material inside the assembly, both
of which can result in a variety of braking issues.
In general, the disc is composed of cast iron, but it can also occasionally be made of
composite materials like ceramic matrix composites or reinforced carbon–carbon. This is
attached to either the axle or the wheel. Brake pads, which are installed on the brake calliper,
act as friction material to slow down the wheel by pressing against the disc's two sides
mechanically, hydraulically, pneumatically, or electromagnetically. The disc and associated
wheel slow down or stop due to friction.
Disc brakes are frequently seen on the front wheels of midrange two-wheelers, including
sports bikes and commuting bikes. In addition to being extensively utilized on the front and
rear wheels of luxury cars and SUVs in conjunction with hydraulic or vacuum brake
actuating mechanisms, the disc braking system is found on the front wheels of the majority of
hatchbacks, entry-level sedans, and MUVs.
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Figure 1.1 : DISC BRAKE

Some of the applications of disc brake are as follows:

1. Better stopping power is required for higher cc performance bikes because of their
increased speed.
2. New cars come with disc brakes on the front or all four wheels.
3. Mountain bikes and bicycles.

1.2 Parts of the disc brake

A disk brake's primary parts are the caliper, caliper support, rotor, and brake pads.

1.2.1 Brake Pads

The vehicle's kinetic energy is transformed into thermal energy by brake pads via friction.
The brake caliper houses two brake pads, each of whose contact surfaces confronts the rotor.
In order to slow and stop the vehicle, the caliper clamps or squeezes the two brake pads onto
the rotating rotor when the brakes are applied hydraulically. A dismal grey coating is left on
the disc when a brake pad transfers tiny amounts of its friction material onto it as a result of
heating up from contact with the rotor. The friction that stops the car is then produced by the
brake pad and disk adhering to one another. Each disc rotor in a disc brake typically has two
brake pads.
The caliper attached to the wheel hub or suspension upright holds these in place and activates
them. However, for optimal performance, racing calipers might use up to six pads with
different frictional qualities arranged in a staggered configuration. Disc wear rates can vary
depending on the material's characteristics, the vehicle's weight, and the pace at which it is
driven. To avoid brake fade, the brake pads often need to be changed on a regular basis. The
majority of brake pads have a mechanism to notify the driver when this is necessary. One
popular method is to create a tiny center groove that, when worn away, signals the end of a
pad's useful life. Other techniques include inserting a thin, soft metal strip into a slot so that
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the brakes can be heard squealing when exposed. When the brake pad becomes thin, a soft
metal wear tab inserted in the pad material can cut off an electric circuit and turn on a
dashboard warning light.

1.1.2 Rotor
The iron disk rotor has heavily machined areas where the brake pads come into touch with it.
The rotor experiences some wear over time, similar to that of the brake pads, typically
manifested as ridges and groves where the brake pad scrapes against it. The pads' wear
pattern as they place themselves against the rotor is precisely the same as this one.
To give the new pads an even contact area to work with when the pads are replaced, the rotor
must be machined smoothly. A rotor can only have a limited amount of material cut off of it
before it breaks down and needs to be replaced.
Every rotor has a minimum thickness measurement stamped on it, and the brake specialist
will measure the rotor both before and after cutting it to ensure that it stays over the required
minimum. A rotor cannot withstand the high heat that brakes typically produce if it is
trimmed below the minimum. The brakes will deteriorate as a result, becoming so ineffective
that you might not be able to stop.

1.1.3 Support and Caliper

Fixed and floating calipers are the two primary varieties of calipers. These are the most
common arrangements, however there are others. If brake fluid leaks from the calipers, they
need to be rebuilt or replaced.

A. Single Piston Floating Calipers

The most widely used and least expensive to produce and maintain are single piston floating
callipers. To orient itself above the rotor, a floating caliper moves or floats in a track within
its support. The hydraulic fluid pushes in two directions as you apply braking pressure. The
inner pad presses on the rotor as a result of the piston being forced against it.
Additionally, it presses the caliper against the opposing side of the rotor by pushing it in the
opposite direction against the outer pad.
Certain cars with two pistons positioned on the same side can also have floating callipers.
More costly vehicles often include two piston floating callipers, which can increase the
sensation of the brakes.

B. Four Piston Fixed Calipers

The support has four piston-fixed callipers that are fixed to it and cannot move. Rather,
the pads are pressed against the rotor by two pistons on each side. Although four piston
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calipers are more effective and have a better feel, they are more costly to manufacture and
maintain. Typically, more costly luxury and high-performance vehicles use this kind of
calliper.

1.1.4 Brake fluid

The hydraulic pressure produced by the brake fluid is used to push the piston outward in the
direction of the disc rotor. They are chemically stable, have lubricating qualities, and a high
boiling point to withstand high temperatures.

1.1.5 Fluid reservoir

A reservoir or tank that holds the brake fluid

1.3 WORKING PRINCIPLE OF DISC BRAKE

Pascal's Law, also known as the Principle of Transmission of Fluid Pressure, is the basis for
how a disk brake operates. "Pressure exerted anywhere in a confined incompressible fluid is
transmitted equally in all directions throughout the fluid such that the pressure ratio (initial
difference) remains the same," according to Pascal's law, which was created by French
mathematician Blaise Pascal.The law merely states that every point in a container
experiences an equal rise in pressure when a pressure is applied to any place in the static
fluid.
The push rod that connects the master cylinder piston to the brake lever or pedal pushes the
master cylinder piston when the lever or pedal is depressed. This movement creates pressure
in the reservoir tank by enabling the master cylinder piston to slide and force the return spring
within the master cylinder bore. Currently, a primary seal permits the reservoir tank's braking
fluid to pass over it and enter the brake hosepipes. The brake fluid won't flow in the other
direction thanks to a secondary seal.
The fluid then presses the caliper piston or pistons after entering the cylinder bore of the
caliper assembly by brake hosepipes.
At this point, the piston and piston ring move in a rolling motion. The brake pad is then
pushed by the caliper piston. This motion stops the brake disc/rotor from rotating by causing
the brake pads to adhere to the brake disc, which generates friction. The car is stopped or
slowed down in this manner by the disk braking system.
The piston ring forces the caliper piston back into the caliper's cylinder bore when the brake
lever or pedal is released, restoring both the caliper piston and the piston ring to their original
configuration. The brake pads are now pushed back to their initial position by the retraction
spring. The master cylinder assembly's return spring forces the master cylinder piston back to
its starting position, enabling the fluid to return to the reservoir through the master cylinder
bore and hosepipe.
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Figure 1.2: Working of disk brake

1.4 TYPES OF DISC BREAK

The following are the various disc brake types that are used:
1.4.1. Single piston
A single piston that is connected to the brake caliper activates the brake pads in a single
piston design, such those seen in two-wheelers. The brake pads flex and scrape against the
disk when you squeeze the brake lever because the brake oil pulls the piston. The disc stops
rotating as a result of friction between the brake pads and the disc, which stops the wheel.
The brake pads revert to their initial position when the brake lever is released. This creates a
space between them and the disc, allowing it to spin freely once more.

1.4.2. Twin piston

Aside from the fact that there are two pistons instead of one, the twin piston design found in
automobiles is nearly the same. To apply the brake in this arrangement, the brake pads are
pushed by the dual pistons. The caliper, which keeps the components of the brake system
together, accepts the brake pads. The hydraulic power applied to the calipers is multiplied by
the oil in the brake master cylinder when the driver presses the brake pedal, which causes the
piston to compress. The brake pads then contract and rub against the disc as a result of the
pistons. The wheel stops because of the friction between the brake pads and the disc, which
stops it from rotating.

1.4.3. Twin Caliper

Twin caliper systems, the third kind, are operated by two calipers and operate on the same
principle as single caliper braking systems. Instead of one calliper, there are two in this style.
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Nonetheless, this kind of mechanism is more frequently found in fast premium vehicles.
More efficient braking is offered by this method.

1.4.4. Ventilated Discs

These days, cars have vented discs. Because of the friction between the brake pads and the
disc, applying the brakes causes the vehicle's kinetic energy to be converted to heat.
Air is facilitated by passageways or an air vent in ventilated discs. As a result, it cools and
stops brake fading.

1.5. The benefits and drawbacks of disc brakes

1.5.1. Disc brakes have the following benefits:

 Compared to drum brakes, disk brakes take less effort (brake torque) to stop the car.
 For the same brake torque, it produces less heat than a drum brake. Because the disk
brake is outside the wheel rim, maintenance is simple.
 It cools down more quickly than a drum brake.
 In a drum brake, the brake drum may be cut if worn-out brake shoes are not replaced
on time. There is no such issue with the disk brake.
 In wet conditions, it is less prone to slide than a drum brake.
 In situations where braking is difficult, it is far safer than a drum brake. The rear
wheel may lock up in such a situation due to the drum brake.

1.5.2. drawbacks of disc braking:

 Disc brakes are far more likely to produce noise. Squeals and squeaks are frequently
produced by their design.
 Compared to drum brake systems, rotors warp more easily. Brake pedal pulsations
can be caused by thickness variances as tiny as 0.0003″ (0.0076 mm), necessitating
replacement or resurfacing because the brake pads are pressing on both sides of the
rotor.
 Due to its inability to self-energize, disc brakes demand greater gripping forces,
necessitating the use of a power booster. Additionally, this hinders their effectiveness
as parking brakes.
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Chapter 2
Literature Review

A computer analysis of the structural and thermal behavior of redesigned disk brake rotors
was conducted by M.H. Pranta et al. [1]. They used Ansys to examine the stress and
temperature distribution after modifying the ventilated disk brake rotor in their experiment
with curved holes, vents, and slots. SolidWorks was used to model the brake, while ANSYS
was used for simulation. A reference disk brake rotor was used to assess the structural and
thermal properties.