Finite Element Analysis of

Disc Brake Rotor

Presented By
Syed Hafeez Peeran Quadri PES1PG19ME011
Mohammad Yusuf PES1PG19ME014
Shahfaissal I Dharwad PES1PG19ME018
Introduction

• The automotive brake is

basically a mechanical
device which inhibits
motion, slowing or stopping
a moving object and thereby
preventing its motion.
• Disc brakes are a two-part
system, first being
Disc/rotor and the second
being the brake caliper
assembly.
Figure 1 : Components
Courtesy : References [1]
Working Of Disc Brakes

Figure 2 : Working Of Disc Brakes

Courtesy : References [1]
Material Selection

• The objective of the present work is to analyze solid disc

rotors against ventilated disc rotors using different materials.
• Many materials are widely available in the market like
ceramic components, carbon-carbon composites, stainless
steels and cast iron components; gray cast iron is apt for
rotors because of its strength and thermal properties, high
temperature resistance and availability.
• Materials Selected
o Gray Cast Iron
o Aluminium Matrix Composites
Material Selection….

Figure 3.1 : Graph for Friction Figure 3.2 : Graph for Compressive
Coefficient Strength
Courtesy : References [2]
Modelling using CATIA

Figure 4.1 : Solid Disc Brake Rotor Figure 4.2 : Ventilated Disc Brake Rotor
Static Structural Analysis using ANSYS For
Material Gray Cast Iron

Solid Disc Rotor Ventilated Disc Rotor

Figure 5.1 & 5.2 : Total Deformation

Contd….

Solid Disc Rotor Ventilated Disc Rotor

Figure 6.1 & 6.2 : Equivalent Elastic Strain

Contd….

Solid Disc Rotor Ventilated Disc Rotor

Figure 7.1 & 7.2 : Equivalent Stress

Static Structural Analysis using ANSYS For
Material Aluminium Matrix Composite

Solid Disc Rotor Ventilated Disc Rotor

Figure 8.1 & 8.2 : Total Deformation

Contd….

Solid Disc Rotor Ventilated Disc Rotor

Figure 9.1 & 9.2 : Equivalent Elastic Strain

Contd….

Solid Disc Rotor Ventilated Disc Rotor

Figure 10.1 & 10.2 : Equivalent Stress

Conclusion

• As a final conclusion and inference, it wouldn’t be wrong to say that solid

rotors have a better performance when compared to vented solid rotors
due to reduced stress, strain, overall deformation.

• Hence, ventilated rotors are generally used in performance cars like sports
cars, ATV’s and UTV’s. However, ventilated rotors are generally weak
and at times difficult to manufacture and hence, usual commercial
vehicles on roads prefer solid disc rotors.

• AMC has got better results but grey cast iron is cost effective
References

[1] Computer Aided Design and Analysis of Disc Brake

Rotors, Pandya Nakul Amrish, Adv Automob Eng 2016.
[2] Manufacturing and Testing of Braking Material - AMC 3,
Shaik Himam Saheb & M. Naveen Kumar, Global Journal of
Researches in Engineering: A Mechanical and Mechanics
Engineering, Volume 17 Issue 6 Version 1.0 Year 2017
Thank You