SSRG International Journal of Mechanical Engineering – (ICEEMST’17) - Special Issue- March 2017

Structural and Thermal Analysis of Disc

Brakes Used In Vehicle Brake System
K.S.J. Prakash, , A. Bala Krishna, D. Naresh, B. Chandra Mouli*
Department of Mechanical Engineering, RISE Krishna Sai Prakasam Group of Institutions, Ongole,
Andhra Pradesh, India

Abstract— In this present work, an attempt of freedom: Temperature at each node; usage notes:
has been made to investigate the effect of stiffness, Useful for modeling curved boundaries).
strength and variations in disc brake rotor design on
the predicted stress and temperature distributions. II. MATERIAL ATTRIBUTES
By identifying the true design features, the extended
service life and long term stability is assured. A The Material chosen for the present work is Cast
transient thermal analysis has been carried out to Iron.
investigate the temperature variation across the disc Density of cast iron = 7100 kg/m3
using axis symmetric elements. Further structural
analysis is also carried out by coupling thermal Young’s Modulus = 125x109 N/m2
analysis. Poisson’s ratio (υ) = 0.25
An attempt is also made to suggest a best Thermal co-efficient of expansion (Kxx) = 54 /°C
combination of material, flange width and wall
thickness used for disc brake rotor, which yields a Thermal conductivity (K) = 54.0 W / m k
low temperature variation across the rotor, less Specific heat (Cp) = 586.0 J/Kg k
deformation, and minimum von Mises stress possible.
Convection film co-efficient (h) = 5.0 W/m2 k
Keywords: Finite Element Analysis, Disc Brake,
Thermal Analysis Applied temperature (t) = 35 °C
Ambient Temperature (tα) = 25 °C
I. INTRODUCTION
Heat flux (q) =3969.623x103 W / m2
A brake is a device by means of which synthetic
frictional opposition is applied to moving machine
member ,in order to bring to a standstill the motion of Thermal boundary conditions
a machine. In the process of performing this function
, the brakes soak up either kinetic energy of the The thermal load is applied axis
moving member or the potential energy given up by symmetrically on the tread of the wheel is a heat flux
substance being lowered by hoists, elevators etc. The (q) of value 5670.891e3 w/m2 and Convection (bulk
energy captivated by brakes is debauched in the form temp 35, Film coefficient 5) is analyzed for 4 seconds
of heat and this heat is debauched in the neighboring of braking i.e the heat generate is going to be
atmosphere. distributed along the profile after the application of
the brakes . Finally the boundary conditions are
Application of brakes on the disc brake rotor of a verified before going for a solution. At the hub
car, heat generation occurs due to friction and this surface the heat transfer is taken as zero i.e. Q = 0.
temperature so generated has to be conducted and Thermal load of q= 5670.891 W/m2 is applied as a
dispersed across the disc rotor cross section. The boundary condition.
condition of braking is very much rigorous and thus
the thermal analysis has to be carried out. Axis- III. RESULTS AND DISCUSSIONS
symmetric analysis is performed which is an exact
representation for this thermal analysis. Linear The following figure 2-9 shows the temperature
thermal analysis is performed to obtain the distribution in the disc brake cross section after
temperature field since conductivity and specific heat carrying out transient thermal analysis for 4 seconds
of the material considered here are independent of braking . The temperature variation is found to be in
temperature. The analysis performed here is transient the range of 25 – 642.9070C.
thermal analysis as temperature distribution varies
with time.
Element considered for thermal analysis:
According to the given specifications the element
type chosen is PLANE 77 (Dimensions: 2-D; shape
or characteristics: Quadrilateral, eight nodes; Degrees

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 SSRG International Journal of Mechanical Engineering – (ICEEMST’17) - Special Issue- March 2017

Figure.2 Temperature Distribution for 10 mm Flange

Width

Figure.3 Heat Flow for 10 mm Flange Width

Figure 1 Disc Brake Rotor

Figure.4 Thermal Deformation for 10 mm Flange

Width

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 SSRG International Journal of Mechanical Engineering – (ICEEMST’17) - Special Issue- March 2017

Figure.5 Thermal Stress for 10 mm Flange Width Figure.8 Thermal Deformation for 12 mm Flange
Width

CAST IRON
PARAMETER
10 mm 12 mm

Temperature distribution(◦C) 466.61 397.24

Heat Flow 7038 8520

Thermal Deformation 0.00011 0.00395

Thermal Stress 120 Mpa 594 Mpa

Figure.6 Temperature Distribution for 12 mm Flange

Width

Figure 9 Thermal Stress for cast Iron with 12 mm

Flange Width

Table 1: Comparison of Temperature, Heat Flow,

Thermal Deformation, Thermal Stress
Figure.7 Heat Flow for 12 mm Flange Width

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 SSRG International Journal of Mechanical Engineering – (ICEEMST’17) - Special Issue- March 2017

From the table we can observe that the minimum

deflection induced is 0.00111mm which is below the
allowable deflection i.e. 0.5 mm. Hence the design is
safe based on the rigidity. The maximum deflection is
found to be 0.00395 mm which is well within the
permissible limits.
IV CONSLUSIONS

The following conclusions are drawn from the

present work.
 An Axis-symmetric analysis of disc brake
has been carried out using Plane 77 and
Plane 82 through ANSYS (F.E.A) software.
 A transient thermal analysis is carried out
using the direct time integration technique
for the application of braking force due to
friction for time duration of 4 seconds.
 The maximum temperature obtained in the
brake disc is at the contact surface and is
observed to be 834.89°C.
 Comparing the different results obtained
from the analysis, it is concluded that disc
brake with 10 mm flange width of material
Cast Iron is the Best possible combination
for the present application.
.
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