MANUFACTURING TECHNOLOGY

DMM2633

TITLE: BRAKE DISC

GROUP 6

NO NAME MATRIC SECTION

NO.
1 MUHAMMAD FARIS IKMAL BIN MB19116 M01
MOHD ARIS
2 NUR KHAIRIN SYAHMI BIN MB19113 M01
NORDIN
3 MUHAMMAD HAZIQ NAQIUDDIN MB19092 M01
BIN MOHD ALI
4 IZANI BIN ISMAIL MB19084 M01
 CONTENTS

CHAPTER 1 (INTRODUCTION)
• INTRODUCTION
• PROBLEM STATEMENT
• OBJECTIVES
• PROJECT SCOPE

CHAPTER 2 (LITERATURE REVIEW)

• EXISTING PRODUCT
• ANYTHING RELATED TO PROJECT

CHAPTER 3 (METHODOLOGY)
• PROJECT FLOW CHART
• PROCESS FLOW

CHAPTER 4 (RESULTS AND DISSCUSSION)

• FINDINGS DURING PROJECT
• ANALYSIS

CHAPTER 5 (CONCLUSION AND RECOMMENDATIONS)

• CONCLUSION
• RECOMMENDATIONS

REFERENCE
ATTACHMENT
CHAPTER 1 (INTRODUCTION)

INTRODUCTION

The word ‘manufacture’ first appeared in English in 1567 and is derived from the Latin
‘manu factus’ which the meaning is ‘made by hand’. The production of any products that
were used or for sale either using machine and labor are called manufacturing. Manufacturing
process means the steps of raw materials transforming into a product. Every product that are
manufactured have their design and material specification to modify the material and turn
them into a product.

Disc brake were began developed in England in the 1890s. One part of the assembly of
wheel’s disc brake is brake disc which also known as rotor is the rotating part of the
assembly. Brake disc were used on motorcycles, scooters, bicycles, heavy vehicles,
automotive use, racing, rail and aircraft. The disc’s design and size are varied depend on what
they were used for. Motorcycles, bicycles and cars discs usually have holes which its function
is for better heat dissipation.
PROBLEM STATEMENT

Disc brake is one of the most important safety components on every vehicle. Disc brake is a
mechanism for slowing or stopping the rotation of vehicles wheels. The mechanism work by
squeezing the brake disc using calipers and creating friction between them. However, the
friction is causing temperature rise and it will have undesirable effects on the components
such as thermal cracks, brake fade, and premature wear. Those undesirable effects will cause
an accident when brake system cannot function properly and the worst case is people will
lose their life.

OBJECTIVES

The main objective of this project is to design and choose the most suitable material for the
brake disc to reduce the risk of getting undesirable effects on the product.

SCOPE OF PROJECT

We design the brake disc and use the most suitable material for the brake disc, so that the
brake disc will be high in quality at the most affordable price for the user.
CHAPTER 2 (LITERATURE REVIEW)

Brake disc is a component part of disc brake which are the mechanism or safety system that
every vehicle (motorcycles, scooters, cars, etc) have. There are a few selections of material
that can be use to product the disc such as bronze, cooper, stainless steel, etc. Our final
material selection for making the disk is cast iron, gray.

During selecting the material

for the disc, we have listed the
required properties of brake
disc and cast iron fulfil most of
the required properties and it
also is considerably cheap
which will reduce the
production cost.

REQUIRED PROPERTIES FOR BRAKE DISC

• High friction coefficient
• High hardness
• High compressive strength
• High wear resistance
• High melting temperature
• High corrosion resistance
• Good thermal conductivity
• Easy to manufacture
• Thermally stable (expansion)
• Low density
• Low cost
 MATERIAL SELECTION

MATERIAL PROPERTIES
Bronze • High thermal conductivity
Cooper • High thermal conductivity
• Low thermal expansion
Cast iron, ductile • Moderate density
• Good thermal conductivity
Cast iron, gray • Thermally stable
• High friction coefficient
• Corrosion resistance
• Low cost
Carbon ceramics • Low density
• Thermally stable
• High thermal conductivity
• High thermal toughness
Stainless steel • High fracture toughness
• Corrosion resistance
Tungsten alloys • Thermally stable
• High fracture toughness
Nickel based alloys • Corrosion resistance
High carbon steel • High fracture toughness
Low alloy steel

FINAL MATERIAL SELECTION

(CAST IRON, GRAY)
• Cheapest • Constant wear rate
• Lightest • High strength
• High thermal conductivity • Easy to manufacture
• High friction coefficient • High wear resistance
• Less
EXISTING thermal expansion
PRODUCT • Corrosion resistance
EXISTING PRODUCT

1. CERAMIC COMPOSITE BRAKE DISC

Source: http://newengineeringpractice.blogspot.com/2011/08/manufacturing-of-brake-
disc.html?m=1

The manufacturing method used in the manufacture of brake discs is the process of metal
casting and, to be more precise, the permanent process of mold casting that takes place in the
manufacture of these brake discs typically gives the final product a good surface finish. The
brake disc material are short carbon fibers, carbon powder, and heat molded resin. These
brake discs are for high performance vehicles.
CHAPTER 3 (METHODOLOGY)

PROJECT FLOW CHART

SURFACE
START DISCUSSION
FINISHING

MANUFACTURING
DISCUSSION CONCLUSION
PROCESS

PROBLEM MATERIAL
FINISH
STATEMENT SELECTION

Figure: Flow Chart

The figure above shows the flow of our project plan on brake disc. The first thing that we do
is doing discussion on what product that we are going to use in this project that related to
Manufacturing Technology (DMM2633) course. Next, we find the problem statement related
to the product and solution to the problem.

Material selection for the product are the most important steps in his project. We need to use
the material that most suitable for the product so that the product quality is high and
affordable. We also have another discussion after a few steps to discuss about the conclusion
of project and anything that we find during the project.
PROCESS FLOW

PROCESS: PERMANENT MOLD CASTING

RAW MATERIAL RE-HEATED MOLDING

STIR THE SURFACE

MELTING
MIXTURE FINISHING

TRANSFER TO ADD SILICON

QUALITY
GRAPHITE CARBIDE
INSPECTION
CRUCIBLES PARTICLES

Equipment and tools for the process:

• Furnaces
• Crucibles
• Permanent mold

Process detail:
i. The raw material was heated up to its melting point in a
heat resistance furnace
ii. The molten material was transferred to graphite crucibles
in semi-solid state
iii. The silicon carbide particles were added into the material
iv. The mixture was stirred to uniform the particle
distribution
v. The mixture was re-heated (become composite)
vi. The mixture was poured into the mold (solidification)
vii. Took out the product and do surface finishing
viii. Inspect the product quality
PERMANENT MOLD CASTING

• Aluminium, magnesium, copper-base alloys and cast iron were commonly used in
permanent mould casting
• Advantages:
-Good surface finish
-Close dimensional control
-Rapid solidification produces finer grain structure (increase strength)

• Preheating facilitates metal flow.

• Coating provides heat dissipation and lubricate the mold surface for easier separation
of the cast product.

• Permanent mold does not collapse, so the mold must be opened before cooling
contraction occurs to prevent cracks.
CHAPTER 4 (RESULT AND DISCUSSION)

RESULT AND DISCUSSION

Our discussion concluded that:

• The manufactured brake disc had high wear resistant (can use for a long time), high
heat resistant (temperature does not rise easily), and rust resistance (does not rust)
• The rings of disc have high consistent frictional value when decelerating vehicles
wheels
• The production cost of disc is cheap and it was light in weight
• The brake disc does not suitable with high performance vehicles such as racing car

Improvement:

• Thermal expansion

Cast iron has less thermal expansion, thus the disc will not expand, bend or stretch and
cracks will not happen easily

• Manufacture

Cast iron is easy to manufacture. Its graphite structured breaks easily in a uniform manner

• Thermal conductivity

Cast iron can transfer the heat from high temperature and high molecular energy to the
lower temperature and lower molecular energy area.

• Cost

Cast iron was the cheapest material that fulfil the required properties for brake disc, so the
production cost will less costly.
ESTIMATE COST:

4KG GRAY CAST IRON

COST TYPE TOTAL (RM)

RAW MATERIAL 11
MACHINING 9.70
CASTING 11
LABOR 8.50
INVENTORY 5.50
OTHERS (ELECTRICITY, 11
ETC)
TOTAL 56.7
CHAPTER 5 (CONCLUSION AND RECOMMENDATIONS)

CONCLUSION

Friction resulting between calipers and brake disc during braking can leads to the crack on
brake disc because of the increasing temperature, Von Mises stress, and the total
deformations of the disc. The most affected area of brake disc is in the inner area of the disk.
Our products are suitable for any vehicles such as car and motorcycle but does not suitable
for high performance vehicles.

RECOMMENDATIONS

Ways to prevent undesirable effects on brake disc (rotor):

• Use material with high yield and fatigue strength for the disc
• Reducing the braking temperature
• Hub-rotor must re-design for eliminating constraint stresses

Long distance and low pressured brake model can reduce the remanent stress of emergency
braking. It also can delay the cracks of initiation and propagation of thermal fatigue to some
extent.
REFERENCE

• https://www.researchgate.net/figure/Material-flow-process-for-MMC-brake-rotor-
production_fig6_221672305
• https://www.slideshare.net/PankajArvikar1/failure-analysis-of-brake-disc
• http://newengineeringpractice.blogspot.com/2011/08/manufacturing-of-brake-
disc.html?m=1
• https://en.m.wikipedia.org/wiki/Disc_brake
• https://www.slideshare.net/PankajArvikar1/failure-analysis-of-brake-disc
• https://matmatch.com/learn/material/cast-iron
• https://www.mdpi.com/1996-1944/12/24/4214/htm
• https://www.brakeandfrontend.com/causes-cures-for-disc-brake-problems/
• https://www.nk-autoparts.com/media/1433/brake-discs-failure-guide.pdf
• https://www.eurekamagazine.co.uk/design-engineering-
features/technology/automotive-brake-disc-provides-high-performance-at-lower-
cost/40189/#:~:text=The%20current%20range%20of%20brake,more%20advanced%2
0cermic%20composite%20brakes.
• Lecture Slide 2 Metal Casting
ATTACHMENT

ORGANIZATITION CHART

MUHAMMAD HAZIQ
NAQIUDDIN BIN
MOHD ALI

IZANI BIN ISMAIL

MUHAMMAD FARIS
NUR KHAIRIN
IKMAL BIN MOHD
SYAHMI BIN NORDIN
ARIS