Materials Today: Proceedings xxx (xxxx) xxx

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An investigation of thermal behaviour of brake disk pad assembly with

Ansys
Camelia Pinca-Bretotean a, Rakesh Bhandari b, Chaitanya Sharma c, Shri Krishna Dhakad d, Preda Cosmin e,
Arun Kumar Sharma f,⇑
a
Engineering and Management Department, Faculty of Engineering of Hunedoara, University of Timisoara, Hunedoara, Romania
b
Department of Mechanical Engineering, School of Engineering and Technology, Sangam University, Bhilwara, Rajasthan, India
c
Department of Mechanical Engineering, Rustamji Institute of Technology, BSF Academy, Tekanpur, Gwalior, India
d
Department of Mechanical Engineering, SATI Vidisha, India
e
Lucian Blaga University of Sibiu, 10 Victoriei Blvd., Sibiu 550024, Romania
f
Department of Mechanical Engineering, School of Engineering and Technology, Sangam University, Bhilwara, Rajasthan, India

a r t i c l e i n f o a b s t r a c t

Article history: The brake disk is a key part of the braking mechanism, the task of it is to slow or stop the vehicle’s wheels,
Available online xxxx on the one side, while the heat produced during the process is dissipated. In this regard, the brake pads
are pressed by mechanical strength on the surface of the brake disks. This study aims to develop a model
Keywords: of a disk brake by use of CATIA V5, on the model, finite element analysis (FEA) done by ANSYS 19 then
Composite material compare it to the findings gained by the original tests. A computational thermo-mechanical study was
ANSYS conducted on this research by use of ANSYS software for disk brake mounting inside a hydraulic brake
Brake pad
system. This study is designed to provide insight into the heat flow behavior within and around a brake
Brake disk
disk during brake testing and simulations. Two cases have been analyzed. Experimental evaluations of a
hydraulic brake system can verify the simulation models. Together with the ten successive brakes,
numerical as well as experimental tests are made. The findings permit a comparison of the numerical
and experimental temperatures to verify the models.
Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Confer-
ence on Materials and System Engineering.

1. Introduction and a low friction dependency of contact pressure, vehicle speed

The key characteristic of the brake disks is to assure a fast heat
dissipation into the atmosphere. The braking mechanism is over-
heated results the braking power decrement. Mechanical as well
as thermal stresses on the disks and the brake pads are extremely
high throughout the braking operation. Thermal stresses normally
are the major concern for the braking mechanism during intense
braking occurring while driving automobiles in towns. Further-
more, the ambient parameters and the kind of surface over which
the automobile operates affect the efficiency of the disk brake
assembly. Most of this may cause severe wear, alterations in shape,
the thermal stresses in extreme braking may be measured. The key
factors that work with each other in the braking mechanism are
friction resistance over a very large spectrum of temperatures
⇑ Corresponding author.
E-mail address: arunresearch88@gmail.com (A.K. Sharma).
and environmental conditions [1].
Evaluating the behavior and performance of the disk brake
assembly under thermal stresses can indeed be determined by
comparing the temperature observed on numerical models
through simulation and the temperature observed while real-
time experiment. In recent years, much attention was paid to
improving the efficiency of the brake disks concerning their perfor-
mance, whenever the brake pads are already in friction. This great
effort contributed to the advancement of products like non-ferrous
copper alloys, Al and carbon-based composites. Numerous scien-
tists investigated thermal dissipation between surface contacts in
vehicle brakes to forecast the distribution of temperature and in
particular the maximum heat temperature throughout braking in
order to prevent failure before such an expected lifecycle. In calcu-
lating the sliding surface temperature, studies have used various
computational tools, including the Finite element method (FEM),
these considerations affect the longevity of the braking system [2].

https://doi.org/10.1016/j.matpr.2021.04.296
2214-7853/Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Conference on Materials and System Engineering.

Please cite this article as: C. Pinca-Bretotean, R. Bhandari, C. Sharma et al., An investigation of thermal behaviour of brake disk pad assembly with Ansys,
Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2021.04.296
C. Pinca-Bretotean, R. Bhandari, C. Sharma et al.
2. Modelling Software’s
Catia V5 is a new CAD software. It allows its users to construct a
right solid pattern or an image drawing. When the component or
assembly’s mathematical model is linked to the characteristics of
the components, obtain a model, which can be used to simulate
and forecast the part or model’s behavior using the finite element
and other simulation applications. To produce the item, the same
solid model may be used and also contains the requisite details
to inspect and assemble the component. This model was used to
create the blueprint for the ventilated disk. Two types of pads
was built precisely the same were then imported to Ansys Work-
bench to test the behavior under various pressure material proper-
ties [3].
ANSYS software is a framework for the greatest range of state-
of-the-art simulations in new engineering technologies. The whole
simulation method is an advanced development tool that leads
users to every move. Drag and drop flexibility is often available
for complicated multiple physics analyses. The ANSYS framework
automatically creates a link to fluid and structural studies, mini-
mizes data storage and facilitates geometric changes analysis
effects [4].
3. Brake disk
Two kinds of disks exist, complete disk and ventilated disk. The
whole disks are made from a simple fabrication process and have
basic geometry; they are usually mounted on the rear axle of the
vehicle. Ventilated disks have more complicated geometry. They
are seen more and more on rear and front cars with two crowns,
which leads to the convective transfer of heat. The ventilated disk
consists of more material than the complete disk, ventilated disk
used for this study since it is more often used by all car brands
around the globe [5].
Material generally used in the brake disk is given below.
3.1. Aluminum alloy
A widely popular lightweight metal is aluminum. In many aero-
space applications aluminum alloy is commonly used. Aluminum
has a range of essential features such as excellent conductivity,
low density, strength, resistance to corrosion and recycling [6].
3.2. Gray cast iron
Gray Cast Iron a kind of cast iron, is known for its grey color,
owing to the existence of graphite. It is the most popular cast iron
as well as the most often used weight-based cast material. A stan-
dard chemical mixture of 2.5 to 4.0 percent carbon and 1 to 3 per-
cent silicone to achieve a graphical microstructure. Grey cast iron’s
key benefits are simple to form and to attain whatever shape. The
content has high compressive strength with damping capability,
serves as a lubricant because of the use of graphite [7].
Table 1
Properties of disks and brake pads in the modeling phase [7]
Type of material Thermal conductivity (W/ Density (kg /
mC) m3)
Disk (Cast iron) 52 7200
Pad 1 (Semi 60 7800
metallic)
Pad 2 (Composite) 38 1270
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3.3. Carbon fiber
Carbon fibers have good strength and the excellent module of
ideal thermal and electrical conductivity with excellent resistance
towards wear relative to other fibers so extensively used in making
of aircraft, nuclear power, industrial, maritime and mechanical
parts such as roller blades, rollers, cams, fan blades and automotive
parts [8].
3.4. Ceramic
Ceramic breaks provide high braking efficiency, good wear
resistance and are extremely light these all critical for high perfor-
mance in driving. As these brake components are ceramic, they dis-
sipate heat effectively, maintaining high output, even after
frequent hard stops. They often emit reduced dust compared to
other brake varieties [9].
4. Materials and method
4.1. Materials
Because of the technological and economic benefits, the brake
disk material is Gray cast iron. There are two separate materials
for the brake pads: one semi- metallic and the other organic com-
posite, brake pad made from this used in small and medium auto-
mobiles. Table 1 shows the characteristics of the brake disk which
made of cast iron and brake pads (semi metallic, composite). In this
study, composites sample made in the laboratory, for road vehicles.
4.2. Modeling
Mechanical energy is converted into heat energy in a braking
mechanism. Absolute heating of the disk and pads during the brak-
ing stage is indicative of this energy. High temperatures may result
from frictional energy. For effective braking efficiency, the dissipa-
tion of the frictional heat produced is essential. The variations in
brake temperature affect axial and radial deformation and impact
on pad-disk interaction. This is why the mechanism can be
regarded as a thermomechanical system that is fully integrated.
In two ways, modeling of pad-disks assembly was done
 Case I: the disks of cast iron ventilated and the semi-metallic
pad.
 Case II cast iron ventilated disk and composite pad of organic
fiber.
CATIA V5 was used for the pads with disk brake modeling and
was assembled for evaluation. For behavior analysis through vary-
ing material properties under various pressure, these elements
were applied in ANSYS Workbench. Modeling simplifies theories
are:
 All of the kinetic energy mostly on the surface of the brake disk
is converted into heat.
Specific heat (J /Kg Poisson’s Coefficient of linear expansion (K- Young Modulus,
C) ratio 1) GPa
447 0.28 1.1 10–5 110
420 0.29 1.2 10–5 19
750 0.21 2.5 10–5 25
2
C. Pinca-Bretotean, R. Bhandari, C. Sharma et al.
Fig. 1. 3D model with the mesh.
 The heat conversion involved in this analysis is through
conduction and convection, radiation may be neglected owing
to the minimal volume of 5 to 10%;
 The brake disk content is assumed homogeneous and isotropic;
 The area of analysis shall be considered axially-symmetrical;
 Throughout the study, inertial forces are negligible;
 The pressure applied to the disk by the brake pad was known to
be uniform.
A finite element approach was used to prepare the structural
model of the disks and pad assembly. Fig. 2 displays the 3D disk
brake concept and Fig. 3 shows the 3D brake pad model. In the
ANSYS workbench, the boundary requirements are used. Thermally
transient analysis of 150 rad/s angular speed after 10 s of braking
was considered for the disk and the brake pads. The initial period
0.01 s and the initial temperature of the disk was considered to
increase by 22°C. The models include structural conditions that
have a defined cylindrical support allowing the y-axis to rotate at
an angular speed of 150 Rad/s.
4.3. Meshing of the disk
The disk brake model for the thermal analysis method is shown
in Fig. 1. To be tested Using a triangular surface masher, a venti-
lated disk brake was measured. In this study, the number of nodes
is 13,450 and the elements are 5718. The model is mashed as well
Fig. 2. 3D model with the mesh.
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as analyzed to obtain the contact zone detailed results of disk and
pad. This is essential since the temperature in this area increases
considerably.
4.4. Meshing of the brake pad
The Fig. 2 below represents the meshed model of the brake pad
used for analysis. From meshing analysis, the results for the num-
ber of nodes are 2895 and 483 elements.
4.5. Boundary conditions
In the ANSYS Workbench module, border conditions shall be
applied by selecting the first mode of the simulation and specifying
its physical properties. These parameters are the initial require-
ments for simulation. After fixing these parameters, the boundaries
of each area are set and the following parameters are defined
Total simulation period = 45 s.
 Increase in the original period = 0.25 s.
 Increase in the minimum initial period = 0.125 s.
 Increase in maximum initial period = 0.5 s.
 Initial disk temperature = 20°C.
 Materials: For brake disk Grey Cast iron and semi-metallic/
ceramic for the brake pads
 The Coefficient of friction = 0.3
Fig. 3 demonstrates the disk-pad brake assembly mesh in finite
elements.
The different pressures 1 MPa and 1.5 MPa were analyzed in
this research on the Disk-Pad assembly. In the lab on the experi-
mental plant, the numerical simulation is validated.
4.6. Thermal stress analysis
The temperature distribution in duration of single-stop braking
was expected to cause thermal stress. The expected compressive
surface stress, which is associated with the increase in the temper-
ature will lead to a resulting material compression in the disk sur-
face since the thermal stresses on the friction surface are much
greater than just the mechanical stresses.
C. Pinca-Bretotean, R. Bhandari, C. Sharma et al.
Fig. 3. Boundary conditions on the disk-pad assembly.
4.7. Validation of experiment
Simulation is a method for conducting conceptual studies using
computer models. These models explain the action over time of
some elements of a real device. A validated model of simulation
can comport in a similar fashion to the phenomenon. The results
generated with the simulation software, taking into consideration
both measures errors and mathematical solving methods, would
be comparable to those obtained experimentally. As the simulated
solution approaches the test solution, the simulation model is
accurate. The objective of the experimental assessments was for
the disks and the brake pads to receive input during 10 consecutive
frequencies. Together with the ten successive brakes assessments
are made. The findings permit contrasts of the numerical and
experimental temperatures to verify the models. The test plant
Fig. 4. Experimental plant for laboratory validation of the models.
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shown in Fig. 4 has been used to verify the simulation models.
To study the laboratory behavior of the pad-disk-brake mounting,
the plant permits sustained braking [10].
5. Results and discussions
During the ten consecutive brakes for pads and disk brake
assembly, the thermal and thermo-mechanical examination was
done. The aim of the combined impact of thermal and mechanical
analysis is to get the simulation nearer to the current operating
conditions when the brake disk is not only subject to a pad load
but also to a temperature effect. Information on the behavior of
pads and disk brake assemblies was collected in numerical and
graphical form in the test reports under dry friction conditions.
The Maximum brake temperature varies depending on the heat
storage capacity of the disk. This would lead to disk asymmetry
due to the increase in temperature. The cumulative number of
deformations found on the disk’s circumference is caused by the
fact that the brake pad deformation due to heat generation. Ther-
mal stresses can interfere with mechanical stresses that result in
a disk cracking. Reduced braking effectiveness of the pad to disk
contact due to thermal deformation.
Fig. 5 reveals that the total disk temperature at the end of the
simulation is 256.19°C for semi-metal pads. Fig. 6 shows that it
is 161.7°C in the case of the composite pad. In Figs. 7 and 8 all tem-
perature values during simulation is showing. In case of pads con-
structed of ceramic material, the temperature at the end of the
simulation phase is lower than in case of a semi-metallic pad. This
indicates that the substance of the brake pad determines the
impact area’s temperature. Improvements in design will modify
the aero-thermal flux behavior of the brake disk because of the
dynamics of the wheelhouse movement.
A few of the temperature images obtained in laboratory tests
while installing a brake pad made of semi-metallic material at
the testing plant. It is apparent that the temperature improves
quite rapidly at the beginning of the braking. The temperature
was 104°C at the fourth brake, and it was 245°C at the end of
breaking. The thermal heat dissipated by convection and radiation
depends both on the disk design and the feature of its substance,
including variation in local emissivity, for such braking frame-
works. Disk surfaces are crucial for the fast heat dissipation of
the disk mass. A comparative study of available thermal images,
C. Pinca-Bretotean, R. Bhandari, C. Sharma et al.
Fig. 5. Temperature and time variation graph for semi-metallic material.
Fig. 6. Graph for Temperature and time variation (composite material Pad).
experimentally during braking in real time, and simulated thermal
images with suitable analytical or numerical model with the same
features, geometric and material properties of a virtual brake disk’s
action under thermal stress evaluated. The best-known, utilized
and admired approach is contactless thermography with regard
to the capture of thermal images in actual environments. in respect
to simulation, methods that enable displays of the temperature
distribution upon the brake disk surface are presently the most
appropriate methods, namely: Finite element method. It is as a
numerical simulation method. This procedure is used in the brake
system design phase. Surface temperature increases during each
braking period the temperature was 183.1°C in the contact region
at the end of the 10 brakes. In both scenarios, temperature
increases are found during breaks. The temperature of the compos-
ite pad was well below the semi metallic pad at the end of the
braking intervals [11].
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In simulation and experimental assessment, the temperature
rises linearly mostly during braking phase. The experimental tem-
peratures are significantly greater than in a simulation test. This is
since a variety of simplifications have been made in the modelling
phase and have resulted in certain variations in outcomes. The
validity of the simulation models is confirmed by no substantial
variations between experimental and computational values.
Regarding thermo-mechanical study, the conclusions are that the
perfect scenario is the one with the brake pad produced of compos-
ite. The temperature released by convection as well as radiation for
these braking systems depends on the disk design and its material
characteristics. Disk surfaces are important because the heat stored
in the volume of the disk is rapidly dispersed. The materials nor-
mally used for creating the brake disk responsible for internal
stresses. A comparative study of thermal pictures in experimental,
real times, during braking and thermal images simulations, in
C. Pinca-Bretotean, R. Bhandari, C. Sharma et al.
Fig. 7. Temperature results for case I.
Fig. 8. Temperature results for case II.
suitable analytical or computational models with the same
geometrical features and the same content of a virtual disk will
evaluate the brake disk behavior. The best-known, utilized and
admired approach is contactless thermography with regard to
the development of thermal images in real time [12].
6. Conclusions
In this article, the thermo-mechanical characteristics of contact
between disk and pad were investigated using ANYS as well as
Inventor simulation software. To test the models, experiments
were done in a hydraulic brake plant laboratory, these results are
as follows: These results are as follows:
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 The FEM has emphasized regions which have been more vulner-
able to mechanical stress and the temperature between the disk
and the brake pad in the contact area.
 Significant deformation occurs in the external radius zone of the
braking disks.
 Taken into account the thermal influence in modeling, the tem-
perature has a substantial impact on the conduct of the disk and
pad brake surface.
 Complete deformation and temperature of the composite brake
pad is less than for the semi-metallic pad within both computa-
tional simulation as well as in experimental assessments.
 The thermo-physical features of the substance through which
the brake pads are produced affect the temperature range.
C. Pinca-Bretotean, R. Bhandari, C. Sharma et al.
In view of simulation, the most appropriate techniques are cur-
rently those that enable the temperature distribution to be shown
on the surface of the brake disk, namely the Finite element Method.
This approach is used throughout the braking mechanism’s design.
The numerical findings confirmed for laboratory studies showing
strong consistency of the model with reality.
CRediT authorship contribution statement
Camelia Pinca-Bretotean: Conceptualization, Investigation,
Resources, Writing - original draft, Writing - review & editing,
Visualization. Rakesh Bhandari: Conceptualization, Investigation,
Resources, Writing - review & editing, Visualization. Chaitanya
Sharma: Conceptualization, Investigation, Resources, Writing -
review & editing, Visualization. Shri Krishna Dhakad: Conceptual-
ization, Investigation, Resources, Writing - review & editing, Visu-
alization. Preda Cosmin: Conceptualization, Investigation,
Resources, Writing - review & editing, Visualization. Arun Kumar
Sharma: Conceptualization, Investigation, Resources, Writing -
review & editing, Visualization.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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