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International Journal of Mechanical Engineering and Technology (IJMET)

Volume 6, Issue 11, Nov 2015, pp. 114-122, Article ID: IJMET_06_11_014
Available online at
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=6&IType=11
ISSN Print: 0976-6340 and ISSN Online: 0976-6359
IAEME Publication

BRAKE DISC ANALYSIS WITH THE HELP


OF ANSYS SOFTWARE
Janvijay Pateriya, Raj Kumar Yadav, Vikas Mukhraiya and Pankaj Singh
Asst. Prof. Department of Mechanical Engineering AIST Sagar M.P
ABSTRACT
There is lot of upgrade in the technology of the automobile these days.
Competition on the speed of vehicles going on in the market. But also this
speed leads to accidents if vehicle dont stop on time. Disc brakes in the
vehicles give much better performance compare to drum to stop the vehicle
also the heat generated during braking force can be easily dissipated as disc
brakes are open to atmosphere. But the main problem is with the material
used in the disc brakes in some vehicle. Manufacturers use disc of steel which
have short life span and the weight is bulky near the tire. If disc loses its shape
wobbling can caused near the tire causing a big problem. The main motto of
this thesis is to improve the strength of the disc by taking various materials for
analysis. The design has been taken from real world. Dimensions of Santro
Xing car has been taken and plotted in three dimensions on solid works.
Materials like Al-ni-co & titanium alloy has been selected for analysis to
compare it with existing material. 3D model has been imported on analysis to
analyze the stresses produced in the disc brake and to check the deformation
occurred in the disc after applying the boundary conditions. After all the
analysis comparison has been made and a result has been concluded for the
best material with good strength.
Key words: Ansys Software, Thermal Analysis, Brake Disc, Cast Iron.
Cite this Article: Janvijay Pateriya, Raj Kumar Yadav, Vikas Mukhraiya and
Pankaj Singh. Brake Disc Analysis with the Help of Ansys Software,
International Journal of Mechanical Engineering and Technology, 6(11),
2015, pp. 114-122.
http://www.iaeme.com/currentissue.asp?JType=IJMET&VType=6&IType=11

1. INTRODUCTION
1.1. BRAKE DISC
A disc brake is a type of brake that uses Calipers with brake pads. To resist the
motion. The brake disc (or rotor) is made of cast-iron, such as a vehicle axle, either to
reduce its rotational speed or to hold it stationary. The development and use of disctype brakes began in England in the 1890s. The first caliper-type automobile disc

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Janvijay Pateriya, Raj Kumar Yadav, Vikas Mukhraiya and Pankaj Singh

brake was patented by Frederick William Lanchester in his Birmingham, UK factory


in 1902 and used successfully on Lanchester cars. So that is a brake disc. This is
stopping the vehicle.

Firstly carry the old brake disc of Hyundai Santro Xing car from car garage. Analysis
each hole, stud, rotor, ventilation slots & his velocity & collect all data like as inner
diameter, outer diameter, hub length etc. & follow the brake disc to whole thesis
works.

And we have designed brake disc on designing software like as catia, solid works.
with properly correct diameter, length,
And import on ANSYS for analysis.
Find out good mashing, total deformation, and equivalent stress.

& Find out total deformation, equivalent stress, equivalent strain, Weight & some
other property of brake disc.

By Using Solid Works Brake Disc

Static Structural Analysis

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Brake Disc Analysis with The Help of Ansys Software

Static analysis is a very important analysis for brake disc. By the help of static
analysis. We can find out the good total deformation, equivalent stress & other
property of static analysis.
A static analysis calculates the effects of steady loading conditions on a structure,
while ignoring inertia and damping effects, such as those caused by time-varying
loads. A static analysis can, however, include steady inertia loads (such as gravity and
rotational velocity), and time-varying loads that can be approximated as static
equivalent loads. Static analysis is probably the most common application of finite
element method the term structural (structure) implies not only civil engineering
structures such as bridges & buildings, but also naval, aeronautical and mechanical
structure such as ship hulls, aircraft bodies, & machine housing, such as piston
machine parts & tools. as well as mechanical component loads in static analysis
Static analysis is used to determine the displacements, stresses, strains, and forces in
structures or components caused by loads that do not induce significant inertia and
damping effects. Steady loading and response conditions are assumed; that is, the
loads and the structure's response are assumed to vary slowly with respect to
time. The kinds of loading that can be applied in a static analysis include.

Externally applied forces and pressures


Temperatures (for thermal strain)
Fluences (for nuclear swelling)

A static analysis can be either linear or nonlinear. All types of nonlinearities are
allowed- large deformations, plasticity, creep, stress stiffening, contact (gap)
elements, hyperelastic elements, etc. This chapter focuses on linear static analyses,
with brief references to nonlinearities.

2. OVERVIEW OF STEPS IN A STATIC ANALYSIS


The procedure for a static analysis consists of three main steps:

Build the model


Apply loads and obtain the solution
Review the results

2. THERMAL ANALYSIS
Thermal analysis is important part of materials science where the properties of
materials are studied as they change with temperature with different condition.
Thermal analysis is a very important analysis for brake disc. By the help of thermal
analysis we can find out the temperature, heat flux & thermal analysis calculates the
other thermal quantities in a system or component. Like as

Temperature (initial &finial)


Heat flux
Temperature distributions

3. TYPES OF THERMAL ANALYSIS


Ansys supposed to thermal analysis

Steady-state thermal analysis


Transient thermal analysis

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3.1. STEADY-STATE THERMAL ANALYSIS


The temperature distribution & other thermal quantities study state thermal analysis
calculate the study of thermal loads on a system or component a study state thermal
analysis performing a transient thermal analysis to determine temperature, thermal
gradient, heat flow rates, and heat flux, in an object, that are caused by thermal loads
that do not vary over time.

3.2. TRANSIENTTHERMALANALYSIS
Transient thermal analysis determine temperature and other thermal quantities that
very over time engineers commonly use temperatures that a transient thermal analysis
calculate as input to structural analysis for thermal stress heat transfer applications. a
transient thermal analysis follows basically the same procedure as a steady-state
thermal analysis.

4. THERMAL BOUNDERY CONDITION


Thermal boundary condition is a major part of thermal analysis. In thermal analysis
we find out ambient temperature & after find out thermal analysis we will be find out
heat flux & check out lowest heat flux in all four alloys which material is a lowest
heat flux. That material is good. Then we will be finding out final temperature on
each material alloy.
E = mcpT
By this equation we will find out final temperature.
Where
E = total energy
m = mass of brake disc
Cp = specific heat
T = temperature difference

4.1. FOR CAST IRON ALLOY


E = mcpT
T =
T
T

=
= 53c

TF = 53+ 32

(where TF is a final temperature)

TF = 85c

4.2. FOR TITENIUM ALLOY


E = mcpT
T =

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Brake Disc Analysis with The Help of Ansys Software

T
T

=
= 43.26c

TF= 43.26 + 32

(where TF is a final temperature)

TF = 75c

4.3. FOR AL-NI-CO ALLOY


E = mcpT
T =
T
T

=
= 56.84c

TF= 56.84+ 32

(where TF is a final temperature)

TF = 87c

4.4. FOR STRUCTURAL STEEL ALLOY


E = mcpT
T =
T
T

=
= 48c

TF= 48+ 32

(where TF is a final temperature)

TF = 80C

By the help of final temperature we will find out heat flux of thermal analysis. on
ansys.

5. ANSYS
ANSYS is engineering analysis software (computer-aided engineering, or CAE). By
the help of this software we can analysis all value for comparing cast iron brake disc.
& other ansys software like as .in Simulation: Structural Mechanics, Metaphysics,
Fluid Dynamics, Explicit Dynamics, Electromagnetics, and Hydrodynamics
(AQWA). Workflow Technology: Ansys Workbench Platform, High-Performance
Computing, Geometry Interfaces, Simulation Process & Data Management. We
compare all four material alloy like as cast iron, structural steel, titanium, AL-NI-CO
alloy.

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6. STRUCTURAL STEEL ALLOY RESULT


In structural steel we will be find out

Total deformation
Equivalent elastic strain
Stress
Factor of safety(f.o.s)
Heat flux

Weight

By the help of these property we will major the good material.

7. TOTAL DEFORMATION
Total deformation in static structural for structural steel alloy

Total Deformation of Brake Disc

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7.1. Equivalent Elastic Strain


Equivalent Elastic Strain in Static Structural for Structural Steel alloy

Equivalent Elastic Strain of Brake Disc

7.2. Equivalent Stress


Equivalent stress in static structural for structural steel alloy

Equivalent Stress of Brake Disc

7.3. Heat Flux


Heat Flux in Thermal Analysis for Structural Steel alloy

Heat Flux of Brake Disc

7.4. Factor of Safety & Weight of Structural Steel Alloy of Brake Disc

Factor of safety of brake disc is 3.3 is minimum & 15 is maximum

Weight of brake disc 3.2 kg

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Janvijay Pateriya, Raj Kumar Yadav, Vikas Mukhraiya and Pankaj Singh

8. FINAL RESULT
Table Details
Properties
Total (Mm) Deformation
Equivalent Stress (Mpa)
Equivalent Elastic Strain
Factor Of Safety
Temperature
(Tf) C
Heat Flux
(W/Mm)
Weight (Kg)

Cast Iron
(ALLOY)
0.0151
75.48
0.00047
3.71

Titanium
(ALLOY)
0.025
73.725
0.00078
12.613

AL-NI-CO
(ALLOY)
0.012
73.099
0.00031
9.5

Structural Steel
(ALLOY)
0.017
74.123
0.00037
3.3

85

75.26

87.5

80

0.4

0.188

0.161

0.570

3.00

1.5

2.84

3.2

9. DISCUSSION
We see that brake disc result is very good for new material alloy like as al-ni-co alloy
& titanium alloy .After compare from cast iron & structural steel. After Having
Modelled Some Error Is Generate in Brake Disc. But through the meshing we
decrease the errors & negative points. & apply both materials al-ni-co, titanium.
&structural steel. By this process of brake disc we create meshing for decreasing error
& negative points. Total deformation is good, stress, strain is good & main aim
reduced weight of brake disc. So we can say that al-ni-co alloy & titanium alloy is a
very good material alloy

10. CONCLUSION
1. By this methodology we can design brake disc on solid works. With standard data of
brake disc.
2. In this methodology of brake disc we create meshing for decreasing error & negative
points.
3. After modelling & meshing we calculate specific perimeter & variable data like as
force & moment of inertia static structural result. & heat flux & final temperature for
thermal analysis.
4. After Having Modelled Some Error Is Generate in Brake Disc.but through the
meshing we decrease the errors & negative points. & apply both materials al-ni-co,
titanium. & structural steel.
5. Broad conclusion of analysis carried out in this chapter is represented by table given
below. This table compares material al-ni-co and material titanium with material
CAST IRONin terms of maximum von misses Stress, maximum total deformation
and weight reduction.
6. Finally we calculate good material through total deformation, stress, strain, weight &
by some other property for brake disc.
7. al-ni-co alloy & titanium alloy is a good material for brake disc from compare to cast
iron & structural steel.

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