International Journal of Analytical, Experimental and Finite Element Analysis

Volume 9, Issue 2, June 2022, pp 34 - 42

https://doi.org/10.26706/ijaefea.2.9.20220508

Design Modification and Analysis

of Disc Brake
Abstract— Many difficulties surround the heating characteristics of brakes when it
comes to their creation, including contact region features, material choice,
development of hot spots, associated physical geometry, and deformations, as brakes
1
Varun S. Shroff are subjected to continuous operation. Therefore, it is must for all vehicles to have
[email protected] proper brake system. In this report there is the modification of the disc and that
Ishan M. Kulkarni2 results in the design are used to carry out analysis on it. The analysis of standard disc
[email protected] brake model and new design using in Ansys is done the Thermal analysis and Modal
analysis also calculate the deflection and Heat flux, Temperature of disc brake model.
Abhishek S. Urankar3
[email protected] Understanding the different forces (action and friction) which are acting on the disc
brake, as well as how the disc brake operates more efficiently, will assist to reduce the
Sumit S. Salunkhe4
number of accidents that occur each day. The primary goal of this research is to
[email protected]
examine the brake disc's thermo-mechanical behavior during braking. The disc
material is changed to carbon-ceramic, and the results of the FEA of the new design
Department of Mechanical
disc are used. This study presents the findings and the disc's future prospects.
Engineering,
JSPM Narhe Technical Campus,
Pune, India Keywords— Disc Brakes, rotor, friction, ANSYS.

I. INTRODUCTION moving vehicle into thermal energy. [14-16].

Brakes are mechanical or sometimes electrical devices Friction brakes are the most popular braking
or components that help to decelerate the vehicle and mechanism in commercial or special-purpose vehicles [17-
eventually stop the vehicle in a certain time and certain 20]. They're often rotating devices with a spinning wear
distance called the stopping distance or the braking surface, such as a disc or drum, and a stationary pad or
distance [1-3]. A device that slows or stops a moving item, shoe [21-23].
in this case, the automobile, and so prevents it from Disc brakes: On the outer surface of a revolving Disc,
moving. [4-6]. Brakes are majorly significant safety shoes or pads flex and create compressive frictional force
systems in any automobile [7-10]. The operation of brakes [24-26]. It's a round metal Disc with pads attached to it. It
is dependent on energy saving [11-13]. Frictional brakes is usually constructed of cast iron [27-30]. The project
are the most prevalent type of brake, in which friction findings have the modified design of a brake rotor, as well
between two objects converts the kinetic energy of a as an analysis of the findings of different analysis [31-33].
Drum brakes: The interior side of a revolving drum
Research Paper – Peer Reviewed
Published online – 09 August 2022 expands and rubs against the shoes or lining [34-36]. When
© 2022 RAME Publishers braking, the shoe or brake lining expands or moves
This is an open access article under the CC BY 4.0 International License
https://creativecommons.org/licenses/by/4.0/ outward to attach itself to the brake drum, creating friction

Cite this article – Varun S. Shroff, Ishan M. Kulkarni, Abhishek S. that slows or stops the drum from rotating. The liner pads
Urankar, Sumit S. Salunkhe, “Design Modification and Analysis of Disc
Brake”, International Journal of Analytical, Experimental and Finite
are mounted in the wheel hub so that they can adhere to the
Element Analysis, RAME Publishers, vol. 9, issue 2, pp. 34-42, 2022. inner surface of the cast iron brake drum, which is made of
https://doi.org/10.26706/ijaefea.2.9.20220508
material.. Due to the lining and drum, drum brakes are

34
Int. J. of Analytical, Experimental and Finite Element Analysis
Mohd Subhan Raza, Sunand Kumar, Mohit Pant

frequently heavier and take up significantly more space A. Material structure of carbon-ceramic brakes
than disc brakes. The ceramic composite material used to make carbon-
The design of a disc brake rotor and an analysis of the ceramic brake discs is a unique property. Carbon fiber-
results of structural and thermal analysis are both included reinforced silicon carbide is used to make the carbon-
in this project report. ceramic brake disc body and the friction layers on either
side. The major matrix components are silicon carbide
(SiC) and elemental silicon (Si). Carbon fibres give
reinforcement for the material (C). The major matrix
component silicon carbide is responsible for the composite
material's high hardness. Carbon fibres have a high
mechanical strength and the fracture toughness that is
required in technological applications. The ceramic
composite material's quasi-ductile characteristics ensure its
Fig 1: Types of Brakes
endurance to high thermal and mechanical loads. As a
Drum brakes: In drum brakes, shoes or lining enlarge
result, carbon fiberreinforced silicon carbide materials
and rub against the interior surface of a rotating drum.. The
combine the benefits of both carbon fiberreinforced carbon
cast iron brake drum is installed in the wheel hub so that
(C/C) and polycrystalline silicon carbide ceramics. C/SiC
the liner pads can be attached to the inner surface of the
materials have elongation at break ranging from 0.1 to 0.3
drum. Additionally, as the brakes are applied, the shoe or
percent. Fiber-reinforced silicon carbide has a unique
brake lining expands or moves outward to attach itself to
profile that makes it a first-choice material for high-
the brake drum, providing the necessary braking force.
performance braking systems. The low weight, hardness,
friction and causing the drum to slow or stop rotating.
and stable characteristics even at high pressure and
Drum brakes are often heavier than disc brakes and take up
temperature, not to mention the resistance to thermal shock
substantially more space owing to the lining and drum,
and quasi-ductility properties, ensure that the brake disc
hence their use in commercial vehicles is limited.
lasts a long time and avoids all of the problems associated
The following is the most typical hydraulic braking
with loading that are typical of traditional brake discs made
configuration:
of grey cast iron. The table one lists the characteristics and
(i) A lever or a brake pedal
distinctions between grey cast iron and carbon ceramic
(ii) Pushrod or actuating rod
discs C/SiC for brake discs made of carbon ceramic grey
(iii) Master cylinder assembly
cast iron (GG-20) Density (g cm-3 )
(iv) Hydraulic lines
Brake disc operating temperature maximum (°C) 900
(v) Brake caliper assembly
700 coefficient of linear thermal expansion (K-1 ) 2.6 - 3.0
9 - 12 Temperature sensitivity (W m-1K -1 ) 40 54 cp, or
specific heat capacity (kJkg-1K -1 ) 0.8 0.5.
TABLE 1
PROPERTIES OF CARBON CERAMIC

C/SiC for carbon ceramic

Properties
brakedisc

Density (g cm-3 ) 2,45

Fig 2: Working of disc brakes

Tensile strength(MPa) 20-40

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Int. J. of Analytical, Experimental and Finite Element Analysis
Finite Element Analysis of Super Austenitic Stainless-Steel Flange

Table 2: Carbon ceramic vs. grey cast iron discs differences

Modulus Of elasticity (GPa) 30
C/SiC for carbon- Gray cast iron
ceramic brake disc (GG-20)
-3
Flexural strength (MPa) 50-80 Density (g cm ) 2,45 7,25
Tensile strength(MPa)
20 - 40 200 - 250
Break Elongation (%) 0.3
Modulus of elasticity
Thermal stability (°C) 1350 (GPa) 30 90 - 110

Flexural strength(MPa)
50 - 80 150 - 250
Maximum operating temperature
900
(Brake disc) (°C) Elongation at break(%)
0.3 0.3 - 0.8

Linear coefficientof thermal Thermal shock resistance

2.6-3.0 (second thermal coefficient
expansion (K-1) > 27.000 < 5.400
K') (W m-1)

Thermal conductivity (Wm-1K -1) Thermal stability(°C)

40 1350 approx. 700

Maximum operating
temperature (brakedisc)
900 700
Carbon-ceramic brake disc benefits Although there are (°C)

many different types of carbon ceramic brake rotors Linear coefficientof thermal
2.6 -
expansion (K-1) 9 - 12
3.0
available today, they all have benefits over iron rotors.
Thermal conductivity
(W m-1K-1) 40 54
B. Weight Reduction

One of the most significant performance benefits of Specific heat capacity

(cp) (kJkg-1K-1) 0.8 0.5
carbon ceramic materials is weight reduction. Carbon
ceramic discs are 50% lighter than cast-iron discs of the
The ceramic composite brake discs' non-metallic
same size due to their low densities. Because of the
construction, which renders them resistant to corrosion and
decrease in the car's unsprung weight and spinning mass,
rust as well as to both liquid and solid road salts, is another
the handling and driving dynamics of the vehicle when
benefit of their design.
braking, accelerating, and turning were improved.
D. Deformation resistance
C. High degree of hardness and low rate of wear
Carbon ceramic materials are more resistant to
Another important characteristic of ceramics is its
distortion or warping at high temperatures because of their
hardness. Compared to conventional grey cast-iron brake
high thermal stability values (1350°C for carbon ceramic
discs, ceramic composite brake discs are more robustly
vs. 700°C for cast iron).
built. The discs' lifespan is increased by this function,
E. Brake fade Reduction
which stops wear and waste. The lifespan of this material is
four times greater than that of steel. Ceramic discs can last High heat stability, heat capacity, and heat dissipation
up to 300,000 kilometres and have a strong abrasion are advantages of carbon ceramic brake discs.
resistance. The material's excessive surface hardness is also Over a wider (and higher) temperature range, carbon
a hint that it should be held to higher friction levels. It ceramic maintains a constant coefficient of friction. In
implies that more braking capacity is available, allowing numerical terms, this indicates that they have roughly twice
heavier weights to be handled with the same size disc. the thermal stability of cast irons. As temperatures rise,
they maintain their braking performance longer in extreme
circumstances, such as racing. Cast iron has a 60% lower

36
Int. J. of Analytical, Experimental and Finite Element Analysis www.rame.org.in
Mohd Subhan Raza, Sunand Kumar, Mohit Pant

specific heat capacity than carbon ceramic, meaning it can that the minimum temperature obtained by both bodies
absorb 60% more heat for a given increase in rotor after a given time instant was almost comparable.
temperature. Thermal conductivity and heat dissipation Manjunath T V and Dr Suresh P M [6] A team from
within the carbon-ceramic composite material are a For both solid and vented discs, Ford Motor Company
function of fibre length. Cast iron rotors take longer to cool (FEM) did a coupled thermal structural study to evaluate
down than long carbon fibre rotors do. the disc's deformation and Von Mises stress were
established.The article determined that the vented type disc
II. LITERATURE REVIEW
brake is superior to the previous one for the current
Faramarz Talati et al [1] extracted the governing heat application.
equations for the disc and the pad in the form of transient Yathish K.O et al [7] The performance check cast iron
heat equations with heat generation that is dependent on and aluminium made rotor discs 6061-SiC-red mud
time and space. According to the paper, in order to prevent composite was investigated. Using software tools such as
a reduction in the friction coefficient between the disc and ANSYS and Hypermesh, the material's influence on
the pad, temperature increases in different brake displacement, stress, contact pressure, contact status, and
components, and brake fluid vaporisation as a result of contact sliding distance of the disc and pad assembly may
excessive heating, the heat produced by friction between be determined.
the disc and the pad should be dissipated to the Chetan T. Jadav and K. R. Gawande [8] did a disc
environment as much as possible. brake examination on a Bajaj Pulsar 150cc. The cost of a
J Hari Narayana Rao et al [2] when combined with pulsar disc rotor was estimated to be roughly 900 dollars,
another field Study of the rotor disc's thermal structure that while the cost of a friction pad was estimated to be around
took into account a variety of disc rotor materials, 150 dollars. The cost and disc weight of the assembly were
including cast iron, stainless steel, and aluminium alloy decreased by 28% and 44%, respectively, by keeping the
Cross drilling holes in the rotor disc for greater heat braking torque constant, lowering the diameter of the rotor
dissipation is part of the work, which involves a disc, and increasing the friction pad area.
comparison between a real solid disc and other design Sreekanth Reddy S et al [9] For the various Aluminium,
discs. Grey Cast Iron, HSS M42, and HSS M2, I modelled a disc
A.Belhocine and M. Bouchetara [3] The thermal brake in CATIA and ran stress analysis in ANSYS
behaviour of the full and vented brake discs of the cars was workbench. Aluminium was shown to be the material with
investigated using ANSYS, taking into account elements the lowest stress caused when the material characteristics,
like braking type, disc geometry, and material stress strain, and displacement values derived from the
Dr Sanjay Chikalthankar et al [4] After creating a solid structural analysis were compared.
model in ProE, the model was exported to Hypermesh for Daanvir Karan Dhir [10] The aim of this study was to
meshing. The natural frequency of the component was see how the temperature of an automotive disc brake rose
discovered using ANSYS vibration analysis. while braking and how it affected disc durability. The rotor
Prashant Sharma et al [5] Researchers have offered an stiffness was calculated as a result of numerical analysis of
analytical model for calculating the contact temperature the heat flux generated and the heat transfer coefficient
distribution on a brake's working surface. The temperature considered.
distribution in a perforated model is significantly better
than that of a simple disc because there is less temperature
differential. After analysing both models, it was discovered

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Int. J. of Analytical, Experimental and Finite Element Analysis
Finite Element Analysis of Super Austenitic Stainless-Steel Flange

III. VALIDATION USING FINITE ELEMENT ANALYSIS

Figure 3: D
Figure3: C and D shows the steady state temperature for
the disc rotor where figure C is used for Experimental
Figure 3: A
Validation

Figure 3: B

Figure 3: A and B shows the total deformation for the

disc rotor where figure A is used for Experimental
Validation.
Figure 3 : E

Figure 3: F

Figure 3: E and F shows the equivalent stresses for

the disc rotor where figure E is used for Experimental
Figure 3: C
Validation.

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Int. J. of Analytical, Experimental and Finite Element Analysis www.rame.org.in
Mohd Subhan Raza, Sunand Kumar, Mohit Pant

IV. RESULTS OF PROPOSED DESIGN

Figure 4 : Total Deformation Graph

This graph represents Total Deformation in which the
blue bars indicate the data used for validation and orange
bars indicates our results.

Figure 7: Proposed Design

Figure 5: Temperature Graph

This graph represents Temperature in which the
blue bars indicate the data used for validation and
orange barsindicates our result.

Figure 6 : Stress Graph

This graph represents Stress Graph in which the
blue bars indicate the data used for validation and
Figure 8: Steady-State Thermal-Temperature
orange bars indicates our results

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Int. J. of Analytical, Experimental and Finite Element Analysis
Finite Element Analysis of Super Austenitic Stainless-Steel Flange

5. The temperature result is 350℃ max temperature and

22℃ minimum temperatures.
6. Total Heat Flux results is 12283 W/𝑚2maximum value
and1.4563e-13 W/𝑚2 minimum value
7. Finally, the analysis we carried in this report is fully
satisfied the conditions

Figure 9 : Steady-State Thermal-Total Heat Flux

VI. FUTURE SCOPE
The future scope of work in this area might include
determining comparison of average of convective heat
transfer coefficients of both and studying transient cooling
behaviour of brakes using this virtual prototype. If the
model improves significantly, it might be used for both
family and sports cars, but this would necessitate a simple
manufacturing process. As a result, manufacturing this sort
of rotor at a reasonable cost will be difficult due to the
design's high cost.
Figure 10: Steady-State Thermal-Directional Heat Flux
Following that, experimental validation would be the
TABLE 3 :
next step. An experimental setup must be created for
RESULT TABLE
experimental validation, in which the three disc rotors will
Parameters Carbon Composite
Max Min be tested: plane rotor disc, perforated disc, and the
suggested one. Based on this discovery, the rotor with the
Temperature 350℃ 22℃
highest heat dissipation will be selected. If the
12283 1.4563e-13
Total Heat Flux recommended rotor's heat dissipation is the highest, a
W/𝑚2 W/𝑚2
vibrational study will be performed to determine which
Directional Heat 9712.9 -9764.1
Flux W/𝑚2 W/𝑚2 rotor has the most vibration, as vibration is major causes of
customer discontent.
V. CONCLUSION The The experimental system would include rotors to
be tested, a motor, and callipers with brake pads, among
This conclusion can be made in light of the simulation other things. Infrared sensors will be used to measure
results mentioned above: temperature, and the findings will be compared to those
1. The new purpose design will be 50% lighter than the obtained in ANSYS for validation. Similarly, vibrations
existing design because of material property of carbon will be measured using a Vibrometer, and the Vibrometer
ceramic. data will be compared to the ANSYS results, resulting in
2. In chapter 1 we studied different types of disc brake validation. If the experimental results are similar to or less
working of disc brake and studied the properties of than the ANSYS findings, then the endeavour was
carbon ceramic. successful.
3. The steady state thermal, total deformation, stress
calculated in a Ansys which is validated in section 3. VII. Acknowledgment

4. The results for carbon ceramic rotor are discussed in The authors would like to express their gratitude to
chapter 4 Prof..Nand Jee Kanu, Professor in mechanical engineering

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Int. J. of Analytical, Experimental and Finite Element Analysis www.rame.org.in
Mohd Subhan Raza, Sunand Kumar, Mohit Pant

department, JSPM NTC, Pune for his valuable guidance Applications. (2021) 85-101. https://doi.org/10.1016/B978-

and practical suggestions. 0-12-819961-9.00012-8.

[11] NJ Kanu, D Patwardhan, E Gupta, UK Vates, GK Singh,
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