1.

Introduction

In today’s growing automotive market the competition for better performance vehicle is
growing enormously. The racing fans involved will surely know the importance of a good
brake system not only for safety but also for staying competitive. The disc brake is a device
for slowing or stopping the rotation of a wheel. A brake disc usually made of cast iron or
ceramic composites includes carbon, Kevlar and silica, is connected to the wheel and the
axle, to stop the wheel. A friction material in the form of brake pads is forced mechanically,
hydraulically, pneumatically or electromagnetically against both sides of the disc. This
friction causes the disc and attached wheel to slow or stop. Generally, the methodologies
like regenerative braking and friction braking system are used in a vehicle. A friction brake
generates frictional forces as two or more surfaces rub against each other, to reduce
movement. Based on the design configurations, vehicle friction brakes can be grouped into
drum and disc brakes. If brake disc are in solid body the heat transfer rate is low. Time
taken for cooling the disc is low. If brake disc are in solid body, the area of contact between
disc and pads are more. In disc brake system a ventilated disc is widely used in automobile
braking system for improved cooling during braking in which the area of contact between
disc and pads remains same. Brake assembly which is commonly used in a bike as shown
in fig.

1.1 Brake Assembly

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1.1Objective

In today’s world the lightweight and durable automobile component is always in demanding. In
this project to find out the best suitable material for manufacturing disk of brake. Which has great
strength as well as long durability

1.2Need:

Today’s industry became an smart industry in all aspects like design ,development, Automation or
etc. to compute with global market industry want to reduce the production and development cost
of product . To reduce the cost of product in last 2 decade computer aided design and analysis
became most popular. Because it allows us to visualize and redetect the failure of object before
they manufacture them in actual. Before some year industry applied trial and error method to insure
that their product is safe or not for use but it require too much time and cost also. To overcome this
CAD and CAE is introduce.
 To Understand the design procedure of Brake disk
 Pre Detect the failure before manufacturing the object
 To Reduce development time and ultimately reduce cost
 To Reduce manufacturing complexes
 To Increase workability

1.3Scope:

As discuss above to compete with global market they want better design which is sustain the given
loading condition as well as they have lower cost as compare to previous design. Present work have
scope in following ways.
 Optimization in vehicle design
 By using special material it can also increase performance
 In formula 1 cars and other special purpose cars this type of design and analysis most
popular

2
2. Designs Methodology

Start

Data from Existing Designs

Analyze data

Mathematical Calculation

Basic Cad Model Preparation

FEA Analysis No
for Safe

Yes
Report Preparation

Detail Drawing

Stop

2.1 Flowchart for Project

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Project is start from collecting data from various bike and their working performance in actual.
This collected data analyses in various way like how much power to weight ration they have and
how they design the disk according to stress and durability factor.

From that cleared that how design is takes place in actual and how it is work. Then collecting the
mathematical calculation to obtain the heat flux generated and how much breaking force and
breaking torque is generated during breaking. By using this input parameter prepare the basic model
of disk. This 3d model is save in universal data exchange format that is IGES. This IGES file then
import in ANSYS 16.2. The value obtain from the mathematical calculation is used for input
parameter in analysis. If model is safe then report is generated if it is not safe then revise the CAD
design.

4
 3. Literature Review

Swapnil R. Abhang
Abhang is investigated and state that the method for single system has been studied and
developed in order to meet safety requirement. Instead of having air bag, good suspension systems,
good handling and safe cornering, there is one most critical system in the vehicle which is brake
systems. In this paper carbon ceramic matrix disc brake material use for calculating normal force,
shear force and piston force. And also calculating the brake distance of disc brake. The standard
disc brake two wheelers model using in Ansys and done the Thermal analysis and Modal analysis
also calculate the deflection and Heat flux, Temperature of disc brake model. 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.

N. Balasubramanyam
He discuss about a transient analysis for the thermo elastic contact problem of the disk
brakes with heat generation is performed using the finite element analysis. To analyze the thermo
elastic phenomenon occurring in the disk brakes, the occupied heat conduction and elastic
equations are solved with contact problems. The numerical simulation for the thermo elastic
behavior of disk brake is obtained in the repeated brake condition. The computational results are
presented for the distribution of heat flux and temperature on each friction surface between the
contacting bodies. Also, thermo elastic instability (TIE) phenomenon (the unstable growth of
contact pressure and temperature) is investigated in the present study, and the influence of the
material properties on the thermo elastic behaviors (the maximum temperature on the friction
surfaces) is investigated to facilitate the conceptual design of the disk brake system. Based on these
numerical results, the thermo elastic behaviors of the carbon-carbon composites with excellent
mechanical properties are also discussed.

Manjunath T V
He is Discuss about the analysis the thermo mechanical behavior of the dry contact of the
brake disc during the braking phase. The coupled thermal-structural analysis is used to determine
the deformation and the Von Misses stress established in the disc for the both solid and ventilated
disc with two different materials to enhance performance of the rotor disc. A comparison between
analytical and results obtained from FEM is done and all the values obtained from the analysis are

5
less than their allowable values. In the aspect of the car accident prevention, the braking
performance of vehicles has been a critical issue. The rotor model heat flux is calculated for the car
moving.

Prof. Mit Patel

Prof. Patel discuss his view about consideration for optimization of technical aspects in
automobile is very important and necessary as there are large numbers of vehicles running on road
today, so that part or product will be durable, safe and affordable to the users. The brakes are very
important aspects of a vehicle as it fulfils all the stopping functions and requirements. As brakes
have to undergo through continuous use, many issues surround their heating characteristics when
it comes to their development, including contact region properties, material choice, development
of hot spots, associated physical geometry, and deformations. The main purpose of this study is to
analysis the thermo-mechanical behavior of the brake disc during the braking phase. The coupled
thermal-structural analysis is used to determine the deformation and the Von Mises stress
established in the disc to enhance performance of the rotor disc. A comparison between analytical
and results obtained from FEA is done and all the values obtained from the analysis are less than
their allowable values. Hence best suitable design, will be suggested based on the performance,
strength and rigidity criteria.

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 4. Braking System

A brake is a mechanical device that inhibits motion by absorbing energy from a moving
system. It is used for slowing or stopping a moving vehicle, wheel, axle, or to prevent its motion,
most often accomplished by means of friction. Most brakes commonly use friction between two
surfaces pressed together to convert the kinetic energy of the moving object into heat, though other
methods of energy conversion may be employed. For example, regenerative braking converts much
of the energy to electrical energy, which may be stored for later use. Other methods convert kinetic
energy into potential energy in such stored forms as pressurized air or pressurized oil. Eddy current
brakes use magnetic fields to convert kinetic energy into electric current in the brake disc, fin, or
rail, which is converted into heat. Still other braking methods even transform kinetic energy into
different forms, for example by transferring the energy to a rotating flywheel. Brakes are generally
applied to rotating axles or wheels, but may also take other forms such as the surface of a moving
fluid (flaps deployed into water or air). Some vehicles use a combination of braking mechanisms,
such as drag racing cars with both wheel brakes and a parachute, or airplanes with both wheel
brakes and drag flaps raised into the air during landing. Since kinetic energy increases quadratic
ally with velocity, an object moving at 10 m/s has 100 times as much energy as one of the same
mass moving at 1 m/s, and consequently the theoretical braking distance, when braking at the
traction limit, is 100 times as long. In practice, fast vehicles usually have significant air drag, and
energy lost to air drag rises quickly with speed.
Almost all wheeled vehicles have a brake of some sort. Even baggage carts and shopping
carts may have them for use on a moving ramp. Most fixed-wing aircraft are fitted with wheel
brakes on the undercarriage. Some aircraft also feature air brakes designed to reduce their speed in
flight. Notable examples include gliders and some World War II-era aircraft, primarily
some fighter aircraft and many dive bombers of the era. Friction brakes on automobiles store
braking heat in the drum brake or disc brake while braking then conduct it to the air gradually.
When traveling downhill some vehicles can use their engines to brake.

When the brake pedal of a modern vehicle with hydraulic brakes is pushed against
the master cylinder, ultimately a piston pushes the brake pad against the brake disc which slows the
wheel down. On the brake drum it is similar as the cylinder pushes the brake shoes against the drum
which also slows the wheel down.

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4.1 Types of brakes:
Brakes is one of the most important element of automobile. There are many types of brakes
available in automobile industries. These are primary brake, Secondary brakes, vacuum brake, air
brake, disk brake, drum brake etc.

The classification of brakes are as follow.

1. According to the purpose:
1.1.Primary or service brake:
This brake is used when the vehicle is in running condition to stop or slow down the
vehicle. This is the main braking system, which is situated in both rear and front wheels of
the vehicle.
1.2. Secondary brakes:
Secondary brakes, which is also known as parking brake or emergency brake , are used to
keep the vehicle stationary. It is generally operated by hand, so also known as hand brake.
The main function of this brake, is to keep the vehicle stationary when it is parked.
2. According to the construction:
2.1. Drum brake:
In this type of brakes a drum is attached to the axle hub whereas on the axle casing is
mounted a back plate. The back plate is made of pressed steal sheet. It provide support for
the expander, anchor and brake shoes. It also protect the drum and shoe assembly from
mud and dust. It also known as the torque plate because it absorbed the complete torque
reaction of the shoe. Two brake shoe is mounted on back plate with friction linings. On or
two retractor spring are used to separate brake shoe from drum when the brakes are not
applied. The brake shoe are anchored at one end, whereas on the other ends force is applied
by means of some brake actuating mechanism which forces the brake shoe against the
revolving drum, so the friction force is generated between drum and the shoe and brake
applied.

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 Fig.2.1 Drum Brake
An adjuster is also provided to compensate for wear of friction lining with use. This brakes
are widely used in motorcycle and the cars.

2.2. Disk brake:

Disk brake consists of a cast iron disc bolted to the wheel hub and a stationary housing
called caliper. The caliper is connected to some stationary part of the vehicle and it cast in
two parts, each part containing a piston. In between each piston and the disc there is a
friction pad held in position by retaining pins, springs plates etc. There are arrangements
in the caliper for the fluid to enter or leave each housing. There passages are also connected
to another one for bleeding. Each cylinder contains a rubber sealing ring between the
cylinder and the piston.

Fig.2.2 Disc Brake Assembly

9
 When the brakes are applied, hydraulically actuated piston move the friction pads into
contact with the disc, applying equal and opposite forces on the later. On releasing the
brakes, the rubber sealing rings act as return springs and retract the pistons and the friction
pads away from the disc.

3. According to the actuation:

3.1. Mechanical brakes:
In this brakes the brake force is applied mechanically used where we needed small force to
braking. This brakes are used in the small vehicle such as in scooters, bikes etc. where
small braking force is needed.

3.2. Hydraulic brakes:

In the hydraulic brakes, brake force is applied by the hydraulic oil. It is one of the most
useful and reliable braking system. This brakes is used in most of passenger cars.

Fig 3.2 Hydraulic braking system

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3.3 Electric brakes:

In this braking system magnetic effect of electricity is used to apply the braking force. The
braking piston and the disk are connected to the electricity. When we want to apply brake,
we start the electricity, which create magnetic effect between brake pad and the disk. So
the brake is applied.

3.4Air brakes:
In the air brakes, air pressure is used to generate the braking force. This braking system is
used in heavy load vehicle i.e. trucks, bus etc.

3.5Vacuum brakes:
These brakes used vacuum to apply the force on brake pads. This is the one of the most
powerful braking system. This brake is used in the big and heavy vehicle i.e. train, heavy
ships etc. Today we have discussed about types of brakes. If you have any query ask by
commenting. If you like this post, don't forgot to share it.

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 5. Disc Brakes

The disk brake is the best brake we have found so far. Disk brakes are used to stop everything from
cars to locomotives and jumbo jets. Disk brakes wear longer, are less affected by water, are self-
adjusting, self-cleaning, less prone to grabbing or pulling and stop better than any other system
around. The main components of a disk brake are the Brake Pads, Rotor, Caliper and Caliper
Support.

Brake Pads
There are two brake pads on each caliper. They are constructed of a metal "shoe" with the lining
riveted or bonded to it. The pads are mounted in the caliper, one on each side of the rotor. Brake
linings used to be made primarily of asbestos because of its heat absorbing properties and quiet
operation; however, due to health risks, asbestos has been outlawed, so new materials are now
being used. Brake pads wear out with use and must be replaced periodically. There are many types
and qualities of pads available. The differences have to do with brake life (how long the new pads
will last) and noise (how quiet they are when you step on the brake). Harder linings tend to last
longer and stop better under heavy use but they may produce an irritating squeal when they are
applied. Technicians that work on brakes usually have a favorite pad that gives a good compromise
that their customers can live with. Brake pads should be checked for wear periodically. If the lining
wears down to the metal brake shoe, then you will have a "Metal-to-Metal" condition where the
shoe rubs directly against the rotor causing severe damage and loss of braking efficiency. Some
brake pads come with a "brake warning sensor" that will emit a squealing noise when the pads are
worn to a point where they should be changed. This noise will usually be heard when your foot
is off the brake and disappear when you step on the brake. If you hear this noise, have your brakes
checked as soon as possible.

5.1 Brake pads

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Master Cylinder
The master cylinder is located in the engine compartment on the firewall, directly in front of the
driver's seat. A typical master cylinder is actually two completely separate master cylinders in one
housing, each handling two wheels. This way if one side fails, you will still be able to stop the car.
The brake warning light on the dash will light if either side fails, alerting you to the problem. Master
cylinders have become very reliable and rarely malfunction; however, the most common problem
that they experience is an internal leak. This will cause the brake pedal to slowly sink to the floor
when your foot applies steady pressure. Letting go of the pedal and immediately stepping on it
again brings the pedal back to normal height.

5.2 master cylinder

Brake Fluid
Brake fluid is a special oil that has specific properties. It is designed to withstand cold temperatures
without thickening as well as very high temperatures without boiling. (If the brake fluid should
boil, it will cause you to have a spongy pedal and the car will be hard to stop.) Brake fluid must
meet standards that are set by the Department of Transportation (DOT). The current standard is
DOT-3, which has a boiling point of 460 F. The brake fluid reservoir is on top of the master
cylinder. Most cars today have a transparent reservoir so that you can see the level without opening
the cover. The brake fluid level will drop slightly as the brake pads wear. This is a normal condition
and no cause for concern. If the level drops noticeably over a short period of time or goes down to
about two thirds full, have your brakes checked as soon as possible. Keep the reservoir covered
except for the amount of time you need to fill it and never leave a can of brake fluid uncovered.
Brake fluid must maintain a high boiling point. Exposure to air will cause the fluid to absorb
moisture, which will lower that boiling point.

Brake Lines
The brake fluid travels from the master cylinder to the wheels through a series of steel tubes
and reinforced rubber hoses. Rubber hoses are used only in places that require flexibility, such as

13
at the front wheels, which move up and down as well as steer. The rest of the system uses non-
corrosive seamless steel tubing with special fittings at all attachment points. If a steel line requires
a repair, the best procedure is to replace the complete line. If this is not practical, a line can be
repaired using special splice fittings that are made for brake system repair. You must never use
brass "compression" fittings or copper tubing to repair a brake system. They are dangerous and
illegal.
Rotor
The disk rotor is made of iron with highly machined surfaces where the brake pads contact it. Just
as the brake pads wear out over time, the rotor also undergoes some wear, usually in the form of
ridges and groves where the brake pad rubs against it. This wear pattern exactly matches the wear
pattern of the pads as they seat themselves to the rotor. When the pads are replaced, the rotor must
be machined smooth to allow the new pads to have an even contact surface to work with. Only a
small amount of material can be machined off of a rotor before it becomes unusable and must be
replaced. A minimum thickness measurement is stamped on every rotor and the technician doing
the brake job will measure the rotor before and after machining it to make sure it doesn't go below
the legal minimum. If a rotor is cut below the minimum, it will not be able to handle the high heat
that brakes normally generate. This will cause the brakes to "fade," greatly reducing their
effectiveness to a point where you may not be able to stop!
Caliper & Support
There are two main types of calipers: Floating calipers and fixed calipers. There are other
configurations but these are the most popular. Calipers must be rebuilt or replaced if they show
signs of leaking brake fluid.

5.3 caliper

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Single Piston Floating Calipers are the most popular and also least costly to manufacture and
service. A floating caliper "floats" or moves in a track in its support so that it can center itself over
the rotor. As you apply brake pressure, the hydraulic fluid pushes in two directions. It forces the
piston against the inner pad, which in turn pushes against the rotor. It also pushes the caliper in the
opposite direction against the outer pad, pressing it against the other side of the rotor. Floating
calipers are also available on some vehicles with two pistons mounted on the same side. Two piston
floating calipers are found on more expensive cars and can provide an improved braking "feel".

Four Piston Fixed Calipers are mounted rigidly to the support and are not allowed to move.
Instead, there are two pistons on each side that press the pads against the rotor. Four piston calipers
have a better feel and are more efficient, but are more expensive to produce and cost more to
service. This type of caliper is usually found on more expensive luxury and high performance cars.

Proportioning valve or Equalizer Valve

These valves are mounted between the master cylinder and the rear wheels. They are designed to
adjust the pressure between the fronts and rear brakes depending on how hard you are stopping.
The shorter you stop, the more of the vehicle's weight is transferred to the front wheels, in some
cases, causing the rear to lift and the front to dive. These valves are designed to direct more pressure
to the front and less pressure to the rear the harder you stop. This minimizes the chance of
premature lockup at the rear wheels.

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 6. Design Calculation

1. Kinetic Energy of Vehicle

𝑚 ×𝑣2
K.E = 2

Where, K. E − kinetic Energy (J)

M − Mass of vehicle (Kg)
V − Linear velocity of vehicle (m/s)

2. Stopping distance of vehicle

Braking distance of vehicle refers to the distance a vehicle will travel from the point
when its brakes are fully applied to when it comes to a complete stop.
The maximum friction force,
F=μ∗M∗g

Hence deceleration of the vehicle: 𝑎 = 𝐹⁄𝑀

Time taken to stop the vehicle: 𝑡 = 𝑉⁄𝑎

3. Stopping Distance
Now, following is other equitation to calculate total stopping distance by considering
reaction time of driver is
𝑣2
Total Stopping distance (SD) = (𝑉 × 𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 𝑡𝑖𝑚𝑒) +2µ𝑔

4. Breaking force
Brake force, also known as Brake Power, is a measure of braking power of a vehicle.
Here following process is given to calculate exact force required to stop vehicle within
stopping distance or stopping time.
a. Tangential braking force: (𝐵𝐹) 𝑡 = 𝐾. 𝐸⁄(𝑆 𝐷)
b. Tangential force on each wheel 𝐹𝑡 = (𝐵𝐹)𝑡⁄4
c. Braking torque on wheel 𝑇𝑤 = 𝐹𝑡 × 𝑅
Where, R − Radius of the tyre (m)

5. Effective rotor radius

rotor diameter Caliper piston diameter
Re = ( 2
)–( 2
)

6. Braking torque on disc

16
 𝑅
Tb = Tw × 𝑟

7. Clamping force
Tb
C=
2×µ×Re

8. Angular velocity of rotor

Velocity V = (π×D×N)
Angular velocity w = 2πN
9. Heat Flux
In a braking system, the mechanical energy is transformed into a calorific energy. This
energy is characterized by a total heating of the disc and pads during the braking phase.
The energy dissipated in the form of heat can generate rises in temperature ranging from
300 °C to 800 °C. Generally, the thermal conductivity of material of the brake pads is
smaller than that of the disc. We consider that the heat quantity produced will be completely
absorbed by the brake disc. Heat generated when applying braking action on disc brake =
kinetic energy
Hg = K.E
Also, heat generation is Hg = md × 𝐶𝑝 × Δt
Where,
md − Mass of disc (Kg)
Cp − specific heat (J/Kg. K)
Δt − temperature difference (℃)
Where, Δt = (tf − ti)
As kinetic energy is entirely converted for 5 seconds the power produced will be
P = K.E/t
Heat flux 𝐻. 𝐹 = (𝑃/𝑡)/𝐴
Where
A = 2×contact area of piston of caliper
=2× (𝜋/4) × [(diameter of rotor)2 - (diameter of rotor - diameter of piston)2]
Design Procedure

Machine design is not guided by any rigid rules; however design is not a random procedure either.
There are a number of factors that can aid a machine design process. It is very important to
understand the process of mechanical design and follow this process to Develop machine/heavy
equipment designs that deliver the best performance.

17
 Understand the Analyse and Evaluate
Analysis of Forces:
Requirements: the Design Mechanism:

Material Analysis
Design of Elements:
and Selection

Creation of Detailed
Design Iteration for
Mechanical
Manufacturing
Drawings:

Understand the Requirements:

The first step of engineering a high performance machine is recognizing the need i.e. understanding
the purpose of design. Preparing a complete statement of the problem that includes details about
the aim or purpose for which the mechanical design project is proposed.
Analyses and Evaluate the Design Mechanism:
Shortlist and analyses various possible mechanisms for the machine. Select the best mechanism for
your design that will give this machine the desired motion.
Analysis of Forces:
Analyses how every component of a machine with fit in and interact with each other, also analyses
what forces act on each and every component of the mechanical equipment and the energy
transmitted by each component.
Design of Elements:
All the components of equipment are subject to stress and other forces during operation. These
stresses affect the strength of the machine. Hence analyzing these stresses is important to design
mechanical equipment that is durable and can endure the stresses of real world working conditions.
Material Analysis and Selection:
Based on the analysis of stresses that work upon the machine components individually select the
appropriate material for machine component design.

18
Design Iteration for Manufacturing:
Design changes, that do not affect the performance of the product but facilitates easy manufacturing
the machine and its components is advisable.
Creation of Detailed Mechanical Drawings:
Create the detailed drawings of each component and assembly of the machine. Complete
pacification using CAD capabilities can be of great assistance for manufacturing process.

19
 7. Material for Brake disc

Grey cast iron

Grey cast iron (a.k.a. gray iron) is a type of iron found in castings known for its grey color
and appearance caused by graphite fractures in the material. Specifically, what makes grey iron
“grey iron,” is the graphite flake structure that is created during the cooling process from the carbon
that is in the component. Grey iron is a result of both the materials used and the process used to
cast a part. In other words, the properties of the grey iron will change depending on what materials
are melted together to pour into the mold as well as the process that is used for casting (it is
primarily the cooling part of the process that defines the characteristics of the cast part versus other
parts of the process.).
The popularity of grey cast iron components is because grey iron is one of the cheapest
types of iron castings to produce. It has acceptable ductility, tensile strength, yield strength, and
impact resistance for most applications. Grey Iron is also excellent in its ability to dampen
vibrations making it ideal for machinery bases and as well as many housing applications. Grey
iron has high thermal conductivity meaning it moves heat more easily through the metal.
A final benefit of grey iron is its ability to withstand thermal cycling well. Thermal cycling
is where the component goes back and forth between warmer and colder temperatures. While
thermal cycling can create stress and premature failure in some types of metal castings, grey iron
has proven to endure the strain of thermal cycling quite well and not stress as easily. While grey
cast iron has less tensile strength and shock resistance than most other castings or even steal, it
has compressive strength that is comparable to low- and medium-carbon steel. These mechanical
properties are controlled by the size and shape of the graphite flakes present in the microstructure.

Grey Cast Iron is made by remelting pig iron. It is an alloy of Carbon and Iron. Small amounts of
Silicon, Phosphorus, Manganese and Sulfur are also present in it. The reasons behind its popularity
are: ability to make complex structures and low cost. In addition, the excellent properties of Grey
Cast Iron have made it one of the most widely used alloys. Its properties are as follows:

20
High Compressive Strength

This strength is defined by the endurance of any metal or alloy to withstand its compressive forces.
Grey Cast Iron has a high compressive strength and that’s why, it is widely used in posts and
columns of buildings. In addition, their compressive strength can be as high as that of some Mild
Steels.
Tensile Strength
there are different varieties of Grey Cast Iron and their tensile strength varies accordingly. Some
varieties show the tensile strength of 5 tons per square inch, some show 19, but on an average their
strength is 7 tons per square inch. However, addition of vanadium can increase the strength of Grey
Cast Iron.
Resistance to Deformation
Grey Cast Iron is highly resistant to deformation and provides a rigid frame. However, if there is
some construction related problem, then even Grey Cast Iron made structure can breakdown.
Low Melting Point
Grey Cast Iron has low melting point – 1140 ºC to 1200 ºC.
Resistance to Oxidation
Grey Cast Iron is highly resistant to rust, which is formed by the reaction of oxygen and Iron. It is
a perfect solution to avoid the problem of corrosion.

Now, let’s look at the uses of Grey Cast Iron as per its class.
Uses of Grey Cast Iron:
Class 300 Grey Iron: Can be used in producing heavy-duty machine tools, bed, presses, high
pressure hydraulic parts, frame, gears, bushings, piston rings, cams, crankshaft, cylinder block,
cylinder head, etc.
Class 200 and class 250 Grey Iron: Can be used in producing gear, cylinder, base, bed, flywheel,
cylinder liners, cylinder block, pistons, brake wheel, gear boxes, pressure valve, coupling plate, etc.
Class 100 and class 150 Grey Iron: Suitable for producing cover body, protective cover, frame,
hand wheels, hammer, floor, handle, box, frame, bed, bearing, pulleys, bench, pump body, pipe,
valve, etc.

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Aluminum Alloy
Aluminum has a far higher heat capacity than most metals, at 0.9 J/g-C. Cast iron by
comparison is only 0.45J/g-C. Of course aluminum has a lower density, but thicker rotors never
bothered anyone.

It's used for rotor hats (the thing that holds the disc to the wheel hub) on higher end brakes,
because it's lighter for the same strength and will conduct heat away to the wheel faster. The issue
is that aluminum is much softer than iron, and has a much lower melting point. Heat is produced at
the surface of a brake disc, and the temperatures they reach easily soften aluminum. This is also
why an aluminum disc covered in steel probably? Won’t work, because brakes experience very
strong forces and aluminum weakens at rather low temperatures, although these people seem to
think it works: Steel Clad Aluminum Brake Rotor (I make no claims as to the effectiveness or lack
thereof of that product, it would definitely be interesting to test those on a track) An interesting
concept would be an iron disc with aluminum strategically bonded around the vanes for greater
thermal capacity, but the gain over just having a bigger iron rotor probably doesn't justify the
complexity and expense.

Carbon Ceramic

A special feature of carbon-ceramic brake disks is the ceramic composite material they are
made from. Both the carbon-ceramic brake disk body and the friction layers applied to each side
consist of carbon fiber-reinforced silicon carbide. The main matrix components are silicon carbide
(SiC) and elemental silicon (Si). The reinforcement of the material is provided by carbon fibers
(C). Silicon carbide, the main matrix component governs great hardness for the composite material.
The carbon fibers make for high mechanical strength and provide the fracture toughness needed in
technical applications. The resulting quasi ductility properties of the ceramic composite material
ensure its resistance to high thermal and mechanical load. Carbon fiber-reinforced silicon carbide
materials thus combine the useful properties of carbon fiber-reinforced carbon (C/C) and
polycrystalline silicon carbide ceramics. The elongation at break of C/SiC materials ranges from
0.1 to 0.3%. This is exceptionally high for ceramics. The entire characteristic profile makes fiber-
reinforced silicon carbide to a first-choice material for high-performance brake systems: Particular
the low weight, the hardness, the stable characteristics also in case of high pressure and temperature,
the resistance to thermal shock and the quasiductility provide long live time of the brake disk and
avoid all problems resulting of loading, which are typical for the classic grey cast iron brake disks.

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At high temperatures, carbon ceramic materials are also less resistant to deformation or warping,
which means that they should last a bit longer than traditional brakes. Finally, carbon ceramic
brakes don’t corrode, even when in contact with water or salt during the winter seasons.

“This feature means that the wear resistance of Carbon Ceramic Material guarantees an
approximate disc life of 150,000 km (93,000 miles) for road use and 2,000 km (2,400 miles) for
extreme track use (e.g. Ferrari Challenge),” Michelini said.

That’s not all. Carbon ceramic brakes also look pretty cool. “The very high technological content
of the carbon ceramic and their superior aesthetic appearance make them the ideal product for sports
and luxury brands,” Brembo communications manager Caroline Fallara says.

These are nice features, but aren’t nearly as important as the biggest advantage of carbon ceramic
materials: weight reduction. Carbon ceramic materials are 50% lighter than cast-iron discs, which
reduce a car’s unsprung weight and should improve handling and driving dynamics.

“Carbon ceramic brake rotors offer tremendous heat dissipation benefits simultaneous with very
low mass,” says Ron Younkin, Chevrolet’s engineering manager of brakes, rear-wheel drive and
performance cars. “The low mass rotors enable superior suspension tuning while their braking
performance on the track allows consistent braking even when pushed by professional drivers who
demand the most from their cars on their race laps.”

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 8. COMPUTER AIDED ENGINEERING (CAE)

CAD (Computer Aided Designing)

Commuter Aided Manufacturing Procedure
Computer-aided design (CAD) is the use of computer systems to aid in the creation, modification,
analysis, or optimization of a design. CAD software is used to increase the productivity of the
designer, improve the quality of design, improve communications through documentation, and to
create a database for manufacturing. CAD output is often in the form of electronic files for print,
machining, or other manufacturing operations. Each stage requires specific knowledge and skills
and often requires the use of specific software.

8.1 Commuter Aided Manufacturing Procedure

Need or Idea

Usually, the design process starts with a defined need. The need can be defined by market research,
by the requirements of a larger body of work (for example airplane part). Sometimes, but more
rarely than you may think, the design process is begun with a new idea or invention. At any rate, a
needs analysis should precede any decision to undertake a project. This includes defining the need
in a highly detailed way, in writing. This is similar to the requirements specification process in
software engineering.

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Research

Professionals tend to research available solutions before beginning their work. There is no need to
"reinvent the wheel". You should study existing solutions and concepts, evaluating their
weaknesses and strengths. Your research should also cover available parts that you can use as a
part of your design. It is obvious, that Internet and search engines like Google are very helpful for
this task. There are also many libraries of standardized parts which you can import into your project.

Concept

Based on your research, start with a high level concept. You should specify the main principles
and major parts. For example, you can consider Diesel or Sterling engines for stationary electric
generators.

Draft

You can choose to create a draft by pen and paper. Some prefer to use simple vector graphics
programs, others even simple CAD (for example Smart Sketch), yet others prefer to start directly
in their main CAD system.

Model Design

2D and 3D modeling in CAD. The designer creates a model with details, and this is the key part
of the design process, and often the most time consuming. This will be described in greater detail
in further lessons. asa ceva

Part Libraries

Standard parts, or parts created by other team members, can be used in your model (you don't have
to reinvent the wheel). Files representing a part can be downloaded from the Internet or local
networks. They are also distributed on CD ROMs or together with CAD as an extension (library).
By putting these predefined parts into your project, you ensure that they are correct and save a lot
of time and effort. When working on a large project, this becomes a requirement to ensure the parts
operate together, swap out equivalent parts, and coordinate distributed teams' work. This was, a
standard part can be inserted into the project by one team member.

Assembly modeling

Parts are assembled into a machine or mechanism. Parts are put together using mating conditions
such as alignment of the axis of two holes. More about how to do this in further lessons. Cad is
used in industries.

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Engineering Drawings

From your 3D models, you generate a set of engineering drawings for manufacturing. These
drawings are then distributed to the departments and individuals responsible for producing that
work. Also, these drawings must be tolerance for proper manufacturing.
Bellow figure shows the basic 2D model of brake disk

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 3D model of Brake Disk

About CATIA V5
CATIA (an acronym of computer aided three-dimensional interactive application) is a multi-
platform software suite for computer-aided design (CAD), computer-aided manufacturing (CAM),
computer-aided engineering (CAE), PLM and 3D, developed by the French company Dassault
Systems. CATIA started as an in-house development in 1977 by French aircraft manufacturer
Avions Marcel Dassault, at that time customer of the CADAM software to develop Dassault's
Mirage fighter jet. It was later adopted by the aerospace, automotive, shipbuilding, and other
industries.

Finite Element Analysis (FEA)

FEA is a numerical method. It is very commonly used in finding the solution of many
problems in engineering. The problem includes deigning of the shaft, truss bridge, buildings heating
and ventilation, fluid flow, electric and magnetic field and so on. The main advantage of using
finite element analysis is that many designs can be tried out for their validity, safety and integrity
using the computer, even before the first prototype is built. Finite element analysis uses the idea of
dividing the large body in to small parts called elements, connected at predefine points called as
nodes. Element behavior is approximated in terms of the nodal variables called degrees of freedom.
Elements are assembled with due consideration of loading and boundary condition. This results in
a finite number of equations. A solution of these equations represents the approximate behavior of

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the problem. The design and analysis have done with the 3D modeling software and FEA technique
standard FEM tool. The analysis is carried out by using the ANSYS software. This gives the
comparison between analytic and numerical value. Part is drawn in CAD software. The CAD
software which is involved in this is CATIA and this part is a call to ANSYS in (.igs) format.

Procedure for FE Analysis

There are a number of steps in the solution procedure using finite element method. All finite
element packages require going through these step;
Specify the
Specify the material
Mesh the object
geometry: properties and
Element type

Apply Boundary
Processing or
condition and Post-processing:
Solution
External Load

Refine the Mesh:

FEA Procedure
Specify the geometry: - In this import the geometry from CAD software to FEA software.
Specify the material properties and Element type: - In this step, the selection of element type is
done and the material properties are given. The Young’s modulus and Poisson’s ratio are the input
for material properties.
Mesh the object: - Here the object is broken in to small elements. This involves defining the type
of element into which structure will be broken as well as specifying how the structure will be
divided in to the element. This subdivision in to elements can either be input by the user or with
same finite element programs can be chosen automatically.
Apply Boundary condition and External Load: - This is followed by specifying the boundary
condition and the external loads are specified.
Processing or Solution: - The modified algebraic equations are solved to find the nodal values of
the primary variable.
Post-processing: - It involves improving the result of processing in to the model. These results are
graphically displaced to enable user case of high deflection and stress.
Refine the Mesh: - For the case of a judge of the accuracy of the result, there is need to increase
or decrease no of elements of a

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9.References

[1] Abhang, S. R. (2014). Design and Analysis of Disc Brake. International Journal of
Engineering Trends and Technology (IJETT).
[2] Balasubramanyam, N. (2013). Design and Analysis of Disc Brake Rotor for a Two.
International Journal of Mechanical and Industrial Technology (IJMIT), 7-12.
[3] Design And Analysis Of Disc Brake With Titanium Alloy. (2015). C.Radhakrishnan.
[4] Manjunath, T. V. (2013). Structural and Thermal Analysis of Rotor Disc. International
Journal of Innovative Research in Science,.
[5] Patel, P. M. (2016). Design of Disc Brake’s Rotor. International Journal of Engineering
Development and Research.
[6] Shinde, H. S. (2017). Structural Analysis of Disc Brake Rotor for Different Materials.
International Research Journal of Engineering and Technology (IRJET).

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