VIVA-Tech International Journal for Research and Innovation Volume 1, Issue 4 (2021)

ISSN(Online): 2581-7280
VIVA Institute of Technology
9thNational Conference on Role of Engineers in Nation Building – 2021 (NCRENB-2021)

Design and Analysis of Motorcycle Disk Brake

Shivam Mishra, Nihar Patil, Kiran Varkhande, Aditi Pimpale
1
(Mechanical Engineering, Viva Institute of Technology /Mumbai University, India)
(Mechanical Engineering, Viva Institute of Technology /Mumbai University, India)
(Mechanical Engineering, Viva Institute of Technology /Mumbai University, India)
(Mechanical Engineering, Viva Institute of Technology /Mumbai University, India)

Abstract: The disc brake is a device for slowing or stopping the rotation of a wheel. A brake disc (or rotor),
usually made of cast iron or ceramic composite, is connected to the wheel and/or the axle. Friction causes the
disc and attached wheel to slow or stop. Brakes convert friction to heat, but if the brake get too hot, they will
cease to work because they cannot dissipate enough heat. This condition of failure is known as brake fade. This
paper discusses the phenomenon of heat distribution on the brake disc during braking. Heat distribution on the
brake disc is caused by kinetic energy changing into mechanical energy. Energy changes occur during the
braking process due to friction between the surface of the disc and a disc pad. The temperature resulting from
this friction rises high. Disc brakes are exposed to large thermal stresses during routine braking and
extraordinary thermal stresses during hard braking. Structural and Thermal analysis is to be done on the disc
brake. The materials used are Cast iron and finding the suitable material and also find the best geometric
design. Structural analysis is done to verify the strength of the disc brake for applied loads. This is important to
understand action force and friction force on the disc brake new material, how disc brake works more
efficiently, which can help to reduce the accident that may happen in each day Thermal analysis is done to
verify thermal properties like thermal gradient and thermal flux etc. Comparison can be done for displacement,
stresses, thermal gradient etc. for the materials to check which material is best. ANSYS is general purpose finite
element analysis (FEA) software package. Analysis of brake rotor includes Structural analysis and Steady state
Thermal analysis for each design. A comparison between the existing brake rotors and proposed new design is
carried out and based on the results the best design is found out by ANSYS software
Keywords -Design, ANSYS, SOLIDWORKS, Disc brake, Friction, Thermal analysis, FEA, Comparison, Heat
flux, Structural analysis, strength, Stress

I. INTRODUCTION
The model of brake disc is designed based on analytical measurements and standard values available from the
standard catalog. The brake disc is designed using SOLIDWORKS. The designed model of disc brake is
analyzed structurally and thermally to study its properties using ANSYS. The models are individually analyzed
for the calculated structural boundary condition and the same as for thermal boundary condition. The alternate
models are analyzed both structurally and thermally.
Different materials used to design disc brake in this study first one are cast iron and other composite materias.
SOLIDWORK used to design disc brake and ANSYS used to thermal analysis. The practical use of finite
element modeling is known as FEA which is best understood during the real problem solving. FEA has been
widely used by the automotive industry. It is a very popular tool for design engineers in the product enlargement
method. FEA allows design engineers to analyze their designs while the designs are still in the procedure of an
adjustable computer aided design (SOLIDWORK) model. This helps and gives flexibility to the design
engineers to go back and forth to implement of the FEA analysis results in the whole design process and
improve the model. It is important to understand the FEA basics, modeling techniques, the inherent errors and
their effects on the quality of the results so as to render FEA as a successful design tool. FEA is also used as a
computational tool for carrying out engineering problem analyze.

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VIVA-Tech International Journal for Research and Innovation Volume 1, Issue 4 (2021)
ISSN(Online): 2581-7280
VIVA Institute of Technology
9thNational Conference on Role of Engineers in Nation Building – 2021 (NCRENB-2021)

II. PROJECT DETAIL

Disc brakes are more familiar from automotive applications where they are used extensively for car and
motorcycle wheels. These typically consist of a cast iron disc, bolted to the wheel hub. This is sandwiched
between two pads actuated by pistons supported in a caliper mounted on the stub shaft. When the brake pedal is
pressed, hydraulically pressurized fluid is forced into the cylinders, pushing the opposing pistons and brake pads
into frictional contact with the disc. Friction material in the form of a brake pad exerts mechanical, hydraulic,
pneumatic or electromagnetic force against both sides of the disc. This friction causes the mounted discs to slow
or stop the wheel. Brake friction generates frictional forces as two or more surfaces rub on each other to reduce
wheel spin. Based on the design configuration, the friction brakes on the vehicle can be grouped into drum
brakes and disc brakes. If the solid-type disc brake disc has a low heat transfer rate, then the time required for
cooling the disc is longer. A ventilated disc brake system is widely used in an automobile braking system which
serves to increase the cooling time of braking in which the area of contact between the disc rotor and disc brake
pad remains the same. The main aim of the work is to investigate the thermal characteristic of the disc brake.
The comparison between the solid disc brake is conducted using a finite element method. The advantages of this
form of braking are steady braking easy ventilation, balancing thrust loads, and design simplicity. There is no
self energizing action, so the braking action is proportional to the applied force.
The main reason of the brake disc overheating is friction. During the working principle of the braking system is
based on friction with the aggressive driving style it increases. This tends to an increase in the temperature of
the brake about 800°C. The heat produced at the boundary between the brake pad and the disk is dissipated from
the disk and pad by convection and radiation. In the model, the rotation is modeled as convection in the disk.
The heat dissipation from the disk and pad surfaces to the surroundings is described by both convection and
radiation.
2.1 Software Uses
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
ANSYS is general-purpose finite element analysis (FEA) software package. Finite Element Analysis is a
numerical method of deconstructing a complex system into very small pieces (of user-designated size) called
elements. The software implements equations that govern the behavior of these elements and solves them all;
creating a comprehensive explanation of how the system acts as a whole. These results then can be presented in
tabulated or graphical forms. This type of analysis is typically used for the design and optimization of a system
far too complex to analyze by hand. Systems that may fit into this category are too complex due to their
geometry, scale, or governing equations.
FEA consists of a computer model of a material or design that is stressed and analyzed for specific
results. It is used in new product design, and existing product refinement. A company is able to verify a
proposed design will be able to perform to the client's specifications prior to manufacturing or construction.
Modifying an existing product or structure is utilized to qualify the product or structure for a new service
condition. In case of structural failure, FEA may be used to help determine the design modifications to meet the
new condition. FEA uses a complex system of points called nodes which make a grid called a mesh. This mesh
is programmed to contain the material and structural properties which define how the structure will react to
certain loading conditions. Nodes are assigned at a certain density throughout the material depending on the
anticipated stress levels of a particular area. In practice, a finite element analysis usually consists of three
principal steps Pre-processing, Analysis, Post- processing.
2.2 Literature Review
PIOTR GRZEŚ, 2011 [1] the aim of this paper was to investigate the thermal information of the solid
disc brake during sudden, emergency braking. In this paper thermal analysis of disc brakes in brake application
was done. To obtain the numerical simulation parabolic heat conduction equation for two dimensional model
was used. The results show that both rotating speed of disc and contact pressure with specific material properties
intensely.
RAJENDRA POHANE, R.G.CHOUDHARI, 2011 [2] FEM model is prepared for contact analysis. A
3D finite element model of the brake pad and the disc is developed to find structural analysis, and transient
analysis. The comparison is done between the solid and ventilated disc keeping the equal material properties and
constraints and using general purpose finite element analysis. This project discusses how general purpose finite
element analysis software can be used to analyze the mechanical stresses & the thermal stresses at disc to pad
surface.
CHOI AND LEE, 2004 [3] presented a research on Finite element analysis of transient behaviors in
disk brakes. A transient analysis for thermo contact problem of disk brakes with frictional heat generation is
performed using the ANSYS. To analyze the thermo elastic condition occurring in disk brakes, the coupled heat
conduction and elastic equations are solved with contact problem. Material used is carbon composite and wear is

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VIVA-Tech International Journal for Research and Innovation Volume 1, Issue 4 (2021)
ISSN(Online): 2581-7280
VIVA Institute of Technology
9thNational Conference on Role of Engineers in Nation Building – 2021 (NCRENB-2021)

assumed zero. The numerical simulation for the thermal behavior of disk brake is obtained in the different brake
condition.
TALATI AND JALALIFAR, 2009 [4] presented a paper on Analysis of heat conduction in a disk
brake system. In this paper, the governing heat equations for the disk and the pad are extracted in the form of
transient heat equations with heat generation that is dependant to time and space. In the derivation of the heat
equations, parameters such as the duration of braking vehicle velocity, geometries and the dimensions of the
brake components, materials of the disk brake have been taken into account.
HARIPAL SINGH AND HARSHDEEP SHERGILL, 2012 [6] presented paper on thermal Analysis of
Disc Brake Using COMSOL in these paper Finite element analysis techniques is used to predict the temperature
distribution and identify the critical temperature of brake disc. Considering all three modes of heat transfer
(conduction, convection and radiation) for three different materials of rotor disc are been used (cast iron, Al and
ceramics). It is concluded that cast iron can be used in brake disc which will give moderate cooling at low
temperature as compared to other. Ceramics has good cooling characteristics but it is costly, can be used in
racing cars where high temperature is produced.
2.3 Problem Definition
2.3.1 Problems associated with disc brakes
Vehicle safety in automobile engineering is a first priority in production of new vehicle. Each
component of a vehicle has been studied and analyzed in order to meet safety requirements, instead of having air
bag good suspension system good handling and safe cornering there is one most critical system in the vehicle
will put a passenger in unsafe position. Therefore it is a must for all vehicles to have proper brake system.
Vehicle braking system is the most important component regards to safety of automobile, therefore so many
researchers conducted a study on brake system Failure of brake especially in two-wheelers have been one of the
major causes for many accidents. The forced stresses acting on the disc brake due to forced braking damages the
disc and eventually it breaks. This shows that no proper material has been chosen while analyzing the disc at
different conditions.
Friction brakes act by generating frictional forces as two or more surfaces rub against each other. The
stopping power or capacity of a friction brake depends on the area in contact and coefficient of friction of the
working surfaces as well as on the actuation pressure applied. Wear occurs on the working surfaces, and the
durability of a given brake (or service life between maintenance) depends on the type of friction material used.
Disc (Rotor) brakes are exposed to large thermal stresses during routine braking and extraordinary thermal
stresses during hard braking. The main objective of this project is to propose a new brake disc design which will
reduce the total deformation and, increase the maximum heat dissipation. If the temperatures reached in braking
become too high, deterioration in braking may result, and in extreme conditions complete failure of the braking
system can occur. It can be difficult to attribute thermal brake failure to motor vehicle accidents as normal
braking operation may return to the vehicle when the temperatures return to below their critical level.
To minimize the above problems in existing disc brake it is necessary to analyze different types of disc
brake, which are commonly used in automobile industry and to propose a new design of brake. Analysis of disc
brake includes Structural analysis and Thermal analysis for each design. A comparison between the existing
brake rotors and proposed new design is carried out and based on the results the best design is found out by
ANSYS software. To design and analyze disc brake made of gray cast iron. Cast Iron materials are used to
design the disc brake. The brake will be then be optimized based on some parameters to get the best possible
design. The brake was created in Solid Works and imported to ANSYS for analysis. Brakes are of utmost
importance in an automobile. Design of brakes, later in this project, is completely based on pure mechanical
modeling and calculation. Brakes in commercial or performance vehicles are used depending on the
specifications required and the braking force required. To design, model a disc.
Modeling is done using SOLIDWORKS. Structural and Thermal analysis is to be done on the disc
brakes using different materials composite. Structural analysis is done on the disc brake to validate the strength
of the disc brake and thermal analysis is done to analyze the thermal properties. Comparison can be done for
deformation stresses, temperature etc. form the different materials to check which material is best. The main
purpose of this project is to study the Thermal analysis of the Materials and the Cast Iron, and. A comparison
between the two materials for the Thermal values and material properties obtained from the Thermal analysis
low thermal gradient material is preferred. Hence best appropriate design, low thermal gradient material cast
iron is chosen for the Disc Brakes for better result. A comparison between the existing brake disc and proposed
new design is carried out and based on the results the best design is found out by ANSYS software.

2.4 Objectives of design and analysis of disc brake:

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VIVA-Tech International Journal for Research and Innovation Volume 1, Issue 4 (2021)
ISSN(Online): 2581-7280
VIVA Institute of Technology
9thNational Conference on Role of Engineers in Nation Building – 2021 (NCRENB-2021)

With the help of analysis, we will design an efficient brake disc which will help to dissipate heatmore
efficiently, thereby reducing the heat transfer to the vehicle and environment.
In order to overcome brake wear, cracks, etc. we will design the brake disc using lighter or composite
materials in order to increase thermal efficiency by a slight margin.
To reduce plastic yielding we will try to use some metal or composite material linings to decrease the
maximum temperature a brake disc will reach at the time of braking.
Analysis and structural analysis is carried out on a disc brake, best design shape of disc brake like
Cutting pattern in disc and material there by a best combination is suggest.

III. METHODOLOGY
3.1 MATERIAL SELECTION
Material selection is a most important step in the process of designing any physical object. In the
context of product design, the main goal of material selection is to minimize cost while meeting good product
performance goals. Systematic selection of the best material for a given application begins with properties and
costs of candidate materials. Material selection is often benefited by the use of material index or performance
index relevant to the desired material properties. The most commonly used brake disc material is cast iron,
because it possesses excellent friction properties, has low cost, retains strength at elevated temperature, has
relative ease of manufacture and is thermally stable. The material selection process generally involves basic
steps which have to be identify before concluding the final material. The material which most meets the
objective is selected as main material and the other materials are kept as a substitute if in-case the material fails
during manufacturing, the next material in the ranking is selected
3.2 Calculation.
To make the calculation the initial condition are taken from site and the assumptions such as weight of
the vehicle, speed of vehicle, weight distribution, coefficient of friction, stopping time, tyre radius, etc. are taken
into account. All the basic theoretical calculation related to disk brake also important before the analysis and
design. Calculation is done as per the problem statements
3.3 Design and Analysis
In order to obtain a 3D model of the disc brake a 2D sketch was prepared in the part sketch in the
modeling software Solid Works. Disc rotors were prepared to compare the results. Two different metals are
design, disc brake in this study first one are cast iron and other composite material. SOLIDWORKS uses a 3D
design approach as design a part, from the initial sketch to the final result, we create a 3D model. From this
model, we can create 2D drawings or mate components consisting of parts or subassemblies to create 3D
assemblies. We can also create 2D drawings of 3D assemblies. When designing a model using SOLIDWORKS,
we can visualize it in three dimensions, the way the model exists once it is manufactured. The model of brake
disc is designed based on analytical measurements and standard values available.
Analysis is used to determine the displacements, stresses, strains, and forces in structures or
components caused by force. Step in the structural analysis is to apply the boundary conditions. Because the
analysis is performed for deformation, displacement, stress and strain, the boundary conditions applied. The
boundary conditions are introduced by selecting the simulation mode, and defining the physical properties of the
material, and the initial conditions of the simulation

IV. FIGURES AND TABLES

Fig.1. ANSYS model of disk brake Fig .2. Motorcycle disk brake

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VIVA-Tech International Journal for Research and Innovation Volume 1, Issue 4 (2021)
ISSN(Online): 2581-7280
VIVA Institute of Technology
9thNational Conference on Role of Engineers in Nation Building – 2021 (NCRENB-2021)

V. CONCLUSION
The above study can provide a useful design and help to improve the brake performance of disc brake
system. Thus analysis was done on the Disc Brake by comparing cast Iron and Composite material. Analysis
has been carried out by cast iron and Composite materials. The results such as deformation, strain, stress,
Temperature and total Heat for each material are determined. While carrying out this project we are able to
study about the 3D modeling software (SOLIDWORKS) and Study about the analyzing software (ANSYS) to
develop our basic knowledge to know about the industrial design. Brakes are of utmost importance in an
automobile. Design of brakes, later in this project, is completely based on pure mechanical modeling and
calculation. Brakes in commercial or performance vehicles are used depending on the specifications required
and the braking force required.

Acknowledgements
I would like to express my gratitude to my Prof. Aditi Pimpale as well as our project in charge Prof. pratik Raut
who give us this golden opportunity to perform Design and Analysis of Motorcycle Disk Brake. I really thankful
to them.

Secondly I would also like thank to my friends who helped me a lot to finish this project within the limited time

REFERENCES

Journal Papers:

[1] Design, analysis and optimization of brake disc made of composite material for a motorcycle, International Journal of
Research Publications.
[2] Design and Analysis of Disc Brake Rotor, International Journal of Applied Engineering Research ISSN 0973-4562 Volume
10, Number 19.
[3] Design and Stress Analysis of Disc Brake, International Journal of Advanced Engineering Research and (IJA-ERA) ISSN:
2454- 2377 Volume – 2, Issue – 11, March – 2017.
[4] Design and Analysis of Braking System for FSAE , IJSRD - International Journal for Scientific Research & Development|
Vol. 6, Issue 02, 2018 | ISSN: 2321-0613.
[5] https://www.researchgate.net/publication/312541551_Computer_Aided_Design_and_Ana lysis_of_Disc_Brake_Rotor

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