Volume 8, Issue 7, July – 2023 International Journal of Innovative Science and Research Technology

ISSN No:-2456-2165

Analyzing the Car Disc Brake using a Combination of

Modelling and Static Structural Techniques
1 2
Haitham Abdullah Khamis AlAdwani Azan Salim Alzahli, 3Mohammed Salim ALabri,
4
Department of Engineering and Technology Zakariya Yahya ALbusaidi
University of Technology and Applied Sciences- Department of Engineering and Technology
ALMusannah, Oman University of Technology and Applied Sciences-
ALMusannah, Oman

Abstract:- A brake is a device that uses friction to slow or effectiveness and avoiding thermal deterioration [6].
stop the motion of a vehicle or machine. component. The Researchers studied heat transfer, cooling, and ventilation to
brakes take on either the kinetic energy of a moving improve brake disc thermal performance. A numerical model
element or the potential energy released by items during was created to analyze the heat transfer and temperature
the process of exhibiting this trait. This paper seeks to distribution in a brake disc and It has been noticed that the
analyze the thermal and mechanical properties of brake maximum temperature increase of a cast iron disc is
discs and pads made of Aluminum oxide when subjected significantly lower than that of stainless steel, thus, based on
to different levels of force, and assess the impact of these its thermal properties, cast iron is the ideal material for disc
forces on the driver's experience. We analyze the total brake production [7]. Cast iron disc brake is prone to
deformation of disc-pads during braking, plus the stress corrosion when it comes in contact with moisture, making it
distribution of brake pads, through a purely mechanical unsuitable for two wheelers, so stainless steel is preferred
method. It found out that Equivalent stress and total [7].In addition, it has observed that the peak temperature
deformation are in direct proportional when applying measured on cast iron disc brake was 56.93 ◦C, with a
different force values. temperature decrease of 33.67 ◦C. While, the maximum heat
recorded on a stainless steel disc brake was 69.81 ◦C and it
Keywords:- Brake Pads and Discs; Aluminum Oxide; Total cooled by 25.64 ◦C[7]. Hence, stainless steel disc exhibited
Deformation; Equivalent Stress. maximum temperature drop, therefore making it ideal for
design purposes[7]. [8] studied thermomechanical behavior
I. INTRODUCTION of disc brake rotor and pads while braking using a
mechanical analysis. The model disc-pads' total deformation
The brake system of a car is vital for providing and stress distribution when braking is ascertained by [8], the
protection and managing the vehicle's movement. The brake data from the thermoelastic coupling, such as contact
disc with pad assembly is one of the most vital elements of pressure field, total deformations of the disc and pads, and
the brake system [1]. The brake disc, or rotor, is necessary Von Mises stress were studied and evaluated[8]. It has been
for slowing or stopping the car by turning kinetic energy into discovered that the Von Mises stress, deformation of the disc
heat energy[2]. The brake pad produces friction against the and contact pressure of the pads all go up significantly when
brake disc to slow down the vehicle. Research has been thermomechanical conditions are combined[8]. Accurately
conducted to improve the performance and durability of car modeling car disc brakes is a must for static structural
brake discs and pads over many years. Research has been analysis. Researchers have employed various modeling
conducted to evaluate the characteristics of brake disc and techniques, including finite element analysis (FEA) and
pad assembly, including its thermal performance and analytical modeling, to represent the complex geometries and
structural response[3]. Selecting and optimizing materials for loading conditions of disc brakes. Understanding the
car brake discs and pads is a fundamental part of their structural behavior and analysis of the brake disc with pad
structural analysis. Investigations of various materials and assembly is essential for optimal performance and safety.
their properties is being done to improve the brake system's Examining the abilities of the brake disc and pad to withstand
performance and longevity. A study was done by [4] different weights and performance while in use is an essential
regarding the influence of different materials on brake disc part of structural analysis [9]. This leads to optimize
thermal and mechanical characteristics. They contrasted cast performance, and boosting the security of automobiles. The
iron, carbon ceramic and aluminum composites, assessing purpose of this paper is to examine the thermal and
which would work best in different environments. Brake mechanical characteristics of the disc brake rotor and pads
discs are typically constructed of cast iron, while some during braking by using Aluminum oxide and to examine the
luxury cars feature aluminum alloy, ceramic, or composite performance of the brakes when exposed to different
oxide film[4]. Considering brake discs' functioning, it's clear intensities of force, and analyze the effect it has on the
that higher-end cars' base materials are superior[4]. While, driver's experience. We establish the extent of the model
ceramics are better at withstanding high temperatures. The disc-pads' total deformation while braking, as well as the
temperature range for liquifying is 1850-3000◦C [4]. It is brake pads' stress distribution, through a strictly mechanical
both lightweight and strong[5]. The thermal performance of analysis.
brake discs and pads is essential for keeping braking

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Volume 8, Issue 7, July – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
II. DESIGN AND ANALYSIS OF
DISC BRAKE

A. Modeling of Disc Brake

This work uses Aluminum oxide for the disc brake
system. Solid works employed to create disc brake, ANSYS
used to analyze mechanical properties. The application of
FEA (Finite Element Analysis) is an effective technique to
solve practical problems. The automotive industry has been
utilizing FEA extensively. Design engineers commonly use
this tool when enlarging products. Design engineers can use
FEA to assess their designs while they are still in the process
of creating a modifiable CAD (Solidworks) model. It allows
the design engineers to move back and forth to utilize FEA
outcomes in the design process and enhance the model. To
use FEA as a successful design tool, it is critical to
comprehend the underlying principles, modeling techniques,
errors, and their ramifications on the accuracy of the output.
FEA is used for problem solving in engineering contexts. It is Fig 3 Extrusion Step
a powerful computational tool. to examine the influence of
the car brake pad and disc when 10 N, 30 N and 50 N of
force are applied to the pad and it is achieved first in
modeling in Solidworks and then in ANSYS as in the
following steps:

Fig 4 Boss-Extrusion Step

Fig 1 Launch Solid Works and Select the Plain White Option

Fig 5 Mirror Step

Fig 2 Create Two Circles

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Volume 8, Issue 7, July – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165

Fig 6 Dimension to Wheel Hub Fig 9 Creating a Wheel Hub and Dust Cap

Fig 7 Creating a Wheel Hub Fig 10 Assembly of Wheel Stud and Cap

Fig 8 Developing the Wheel Stud and Cap Fig 11 Dimensions to Create Pad

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Volume 8, Issue 7, July – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
Table 2 Material Engineering Data

Fig 12 Pads and Disc Assembly

Fig 14 Geometry Step

Fig 13 Pads and Disc Assembly

Table 1 Material Assignment in ANSYS

Fig 15 Model Import from Solid Works

Fig 16 Mesh Step

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Volume 8, Issue 7, July – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
III. RESULT

 For 10 N:

Fig 17 Boundary Conditions (Fixed Support) Fig 20 Solution of Total Deformation when Applied
Force is 10 N

Fig 21 Solution of Equivalent Stress when Applied

Force is 10 N
Fig 18 Boundary Conditions (Force Input Value)
 For 30 N:

Fig 19 Solution Information (Total Deformation And Fig 22 Solution of Total Deformation when
Equivalent Stress) Applied Force is 30 N

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Volume 8, Issue 7, July – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
IV. DISCUSSIONS

The temperature fluctuates depending on the duration of

contact between the pad and disc, revolutions per minute of
the disc, and the material used to make the brake. The rapid
physical action during braking, primarily friction, causes a
noticeable expansion in performance due to the small plastic
deformation of the surface it touches. The thermometer goes
up to 401.55°C, its highest point. It diminishes rapidly.
Consequently, the range of heat is relatively sluggish. The
ventilated disc shows a cooling of roughly 60° C when
compared to other scenarios. The design of the brake disc's
ventilation has a large effect on the cooling efficiency of the
system. In addition, total deformation occurred with respect
to varying forces. Total deformation at a minimum and
maximum force. This implies that the brake disc needs to be
able to withstand deformation. This study indicates that force
Fig 23 Solution of Equivalent Stress when Applied
and deformation are usually proportional as shown in Table 3
Force is 30 N
and Figure 26
 For 50 N
Table 3 Force (N) Versus Total Deformation (m)

Fig 24 Solution of Total Deformation when Applied

Force is 50 N

Fig 26 Force (N) Versus Total Deformation (m)

Equivalent Stress occurred with respect to varying in

force. Equivalent Stress at minimum and maximum force
range. In this research work, equivalent stress increases as
Fig 25 Solution of Equivalent Stress when Applied force increases as shown in Table 4 and figure 27.
Force is 50 N

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Volume 8, Issue 7, July – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
Table 4 Force (N) Versus Equivalent Stress (Pa) REFERENCES

[1 ]. Günay, Mustafa, Mehmet Erdi Korkmaz, and

Ramazan Özmen. "An investigation on braking
systems used in railway vehicles." Engineering
Science and Technology, an International Journal 23.2
(2020): 421-431.
[2 ]. Choudhary, Akshit, et al. "Coupled thermal and
structural analysis of disc brake rotor with varying
angle of rotation of ventilation holes." Materials
Today: Proceedings 56 (2022): 834-844.
[3 ]. Pranta, M. H., et al. "A computational study on
structural and thermal behavior of modified disk brake
rotors." Alexandria Engineering Journal 61.3 (2022):
1882-1890.
[4 ]. Li, Wanyang, et al. "Comprehensive analysis on the
performance and material of automobile brake discs."
Metals 10.3 (2020): 377.
[5 ]. Venkatesh, S.; Murugapoopathiraja, K. Scoping
review of brake friction material for automotive.
Mater. Today Proc. 2019, 16, 927–933
[6 ]. Mulani, Shoaib Munir, et al. "A review on recent
development and challenges in automotive brake pad-
disc system." Materials Today: Proceedings 56
(2022): 447-454.
[7 ]. Dhakar, P. S. "Thermal analysis of disc brake using
ANSYS." Int. J. Tech. Innov. Mod. Eng. Sci 4 (2018):
8-17.
[8 ]. Belhocine, Ali. "Finite Element Analysis of
Automotive Disk Brake and Pad in Frictional Model
Contact." ADMT Journal 7.4 (2014).
Fig 27 Force (N) Versus Equivalent Stress (Pa) [9 ]. Singh, Mandeep, et al. "Design and Analysis of an
Automobile Disc Brake Rotor by Using Hybrid
V. CONCLUSION AND SUGGESTION Aluminium Metal Matrix Composite for High
Reliability." Journal of Composites Science 7.6
This article discussed analyzing the thermal and (2023): 24
mechanical behavior of the dry contact between the pads and
disc when braking. It is demonstrated that the ventilation
system is critical to the cooling of the discs and offers good
high temperature resistance The study revealed a perfect
partnership between the temperature and stress fields during
braking. The temperature, Von Mises stress, total disc
deformations, and pad contact pressures all rise as the
temperature rises. Results of this evaluation are in agreement
with other literature. For instance, Equivalent stress and total
deformation are in direct proportional when applying
different force values. In order to gain a better understanding
of the thermomechanical contact between the disc and pads,
three suggested methods of expanding the next disc brake
research have been compiled. The following are some
suggestions:

 Examining the model's performance through

experimentation
 Investigation of friction and vibration of the contact disc-
pads
 Interference created by frictional impact forces.

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