See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/318440458

Optimization of the Brake Parameter for a Disc Brake System to Improve the
Heat Dissipation using Taguchi Method

Article · July 2017

CITATIONS READS

4 1,274

2 authors, including:

Ritesh R Bhat
Manipal Academy of Higher Education
37 PUBLICATIONS   139 CITATIONS   

SEE PROFILE

Some of the authors of this publication are also working on these related projects:

Investigation of delamination during drilling of glass fiber reinforced polymer composites View project

Investigation of the productivity improvement in manufacturing or service sector with the implementation of lean manufacturing techniques View project

All content following this page was uploaded by Ritesh R Bhat on 10 August 2018.

The user has requested enhancement of the downloaded file.

International Journal of Mechanical Engineering and Technology (IJMET)
Volume 8, Issue 7, July 2017, pp. 44–52, Article ID: IJMET_08_07_00
IJM 07_006
Available online at http://www.iaeme.com/IJMET/issues.asp?JType=IJME
http://www.iaeme.com/IJME asp?JType=IJMET&VType=8&IType=7
asp?JType=IJMET&VType=8&IType=7
ISSN Print: 0976
0976-6340
6340 and ISSN Online: 0976-6359
0976

© IAEME Publication Scopus Indexed

OPTIMIZATION OF THE BRAKE PARAMETER

FOR A DISC BRAKE SYS
SYSTEM
TEM TO IMPROVE
THE HEAT DISSIPATION USING TAGUCHI
METHOD
Ritesh Bhat
Department of Mechanical & Manufacturing Engineering,
Manipal Institute
Institut of Technology, Manipal, India

Kah Seng Lee

Graduate Student, Department of Mechanical Engineering,
Manipal Internatio
International
nal University, Nilai, Malaysia

ABSTRACT
Disc brake rotor was proved to have better heat dissipation performance than
drum brake as more exposed surfaces had provid provided
ed to improve the heat transfer.
However, overheated surfaces that caused brake fade was still a possibility. In this
research, three ventilation parameters of disc brake rotor (number of rotor holes,
number of slots and diameter of rotor holes) associated with three factor values levels
ranging from minimum, average and maximum were studied experimentally by
utilising of Taguchi method. The result obtained
obtained from the experiment has pointed that
disc brake rotor design with twenty
twenty--four
four 4mm diameter holes and six slots was the
optimum design while number of ventilation slots was the most significant parameter
that contributed at a rate of 45.25% in heat dissipation performance.
Key words: Disk brake, Heat dissipation, Taguchi method, Ventilated disc brake rotor
rotor.
Cite this Article:
Article Ritesh Bhat and Kah Seng LeeLee. Optimization of the Brake
Parameter for a Disc Brake System
System to Improve the Heat Dissipation using Taguchi
Method
Method. International Journal of Mechanical Engineering and Technology
Technology,, 8(7),
2017, pp. 44
44–52
52.
http://www.i
http://www.iaeme.com/IJME
aeme.com/IJME
aeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=7
asp?JType=IJMET&VType=8&IType=7

1. INTRODUCTION
The brake system was worked under the principle by utilising of the friction pads to rub
against the respective metal moving surface in order to attain of the stopping motion of certain
mechanism. The translation of kinetic energy to heat energy had stopped the moving
mechanism. In automotive, there are drum brake system and disc brake system. Disc brake
system was more preferred as its characteristics that of higher braking power, longer lifespan,
and better heat di
dissipation.
ssipation.

http://www.iaeme.com/IJMET/index.
http://www.iaeme.com/IJMET/index.asp
asp 44 editor@iaeme.com
editor@iaeme.com
 Ritesh Bhat and Kah Seng Lee

Smaller contact area between the brake rotor and brake pad had increased the applied
pressure [1]. Disc brake rotor provided more surface exposure to the atmosphere that
minimized the possibility of thermal failure [2]. However, high temperature built up on the
disc brake rotor at certain conditions such as continuous braking situation was still giving the
chances for brake fade to be happening.
Therefore, ventilation features had been implied in the design of disc brake rotor to
enhance the cooling performance. Holes, slots or vanes that added to the disc brake rotor
formed extra channels for the air to pass through, which improved the air mass flow rate to
create a better cooling effect.
By employing appropriate parameters for the respective ventilation features, the pros and
cons were able to be balanced. The performance of the disc brake rotor can be improved with
no significant effect at all with suitable design of ventilation features. In this research, various
parameters of ventilation features for disc brake rotor had been studied by using of Taguchi
method. Actual experimentation had been done by adopting of respective method to improve
the effectiveness of the optimization process. Through this, the optimum design of ventilation
features and the parameter that gave the most significant effect in heat dissipation
performance had been identified in an efficient way. The optimum design was proved to be
giving the optimum performance in heat dissipation through the confirmation experiment.

2. LITERATURE REVIEW
2.1. Thermal Analysis, Structural Analysis and Brake Performance
Disc brake rotor was needed to be ensured in the optimum operational temperature to
dissipate the heat on time for each time of kinetic energy conversion. The disc brake rotor was
acted as heat sink, which excess heat could reduce the friction between contact surfaces [3]. It
was important for heat to be dissipated as high temperature can cause brake fade or thermo-
elastic deformation on the rotor surface [4]. Nevertheless, solid disc brake rotor ranked the
least in heat dissipation performance. Ventilation designed disc brake rotor gave better
cooling and higher heat flux than the solid brake rotor [3].
It had been said that the heat transfer of disc brake rotor was directly proportional to the
number of ventilation features that applied to the design [5]. With combination of different
ventilation features, it can greatly improve the cooling effect. However, suitable design should
be employed to attain this effect. Different types of design features in each ventilation
parameter could affect the performance of the disc brake rotor [6]. Ranging effects could be
happened with different design of ventilation features. In order to reach the equity between
the pros and cons, appropriate ventilation features with suitable specifications should be
considered in designing of disc brake rotor with respect to the intended application of vehicle
[6].
Compared to side-ventilation features, axial ventilation features which applied directly on
the disc brake rotor surface resulted a more desirable heat dissipation [7]. The reduction of
surface area of the rotor had improved the heat transfer on the respective surface [8]. Some
research had also indicated that the ventilation features or disc brake properties which could
also contribute to the braking performance.
Cross-drilled holes on disc brake rotor guided more fresh air due to pressure drop around
holes area whereby increased the heat transfer [9]. Slotted disc brake rotor able to reduce heat
generation at a high rate when combined with radial ventilation vanes [5].
In terms of material, cast iron is still the most suitable raw material for disc brake rotor in
present automotive application [9]. Cast iron retained the least thermal energy on rotor surface
as measured in terms of temperature, which proved it gave the best heat ventilation

http://www.iaeme.com/IJMET/index.asp 45 editor@iaeme.com
 Optimization of the Brake Parameter for a Disc Brake System to Improve the Heat Dissipation
using Taguchi Method

performance [10]. Also, cast iron had a higher operating temperature, whereas most
alternative materials were not able to reach without additional of the friction layer [11].
Although there are new materials which seem to replace the current; however, in the
economical aspect, cast iron is still the most appropriate.

2.2. Taguchi Robust Design and Development Method

Taguchi method, by Dr. Genichi Taguchi, was initially invented to assist industry
development in Japan in order to manufacture high-quality products with reasonable pricing
had become one of the methods that used worldwide in product optimization process. It was a
simple optimization method that suited most of the situation and gave the best experimental
efficiency [12].
Inner and outer arrays that proposed by Taguchi method was able to obtain the desired
information regarding the relationship between primary and noise variable [13]. Thus,
Taguchi robust design and development method was seemed to be the most suitable method
in dealing with this research.
Moreover, orthogonal arrays utilised in Taguchi method had efficiently determined the
best setting combination of parameters with least experiment performed, which allowed it to
be powerful and robust in optimization process [14]. The orthogonal arrays randomised the
factor levels in each parameter and organised it into different experiment variables setup
accordingly. The method reduced the bias on result by considering the relationship between
factors. Significant performance with high result accuracy attained by dealing multiple factors
at one time [15]. Other than that, the robustness of the method could be achieved by correctly
selecting of signal-to-noise ratio with proper defining of variables into respective categories
[16].
As the Taguchi method was emphasized on the factor that had direct effects on the
product functional performance, whereas environmental factors were treated as noise, it was
suitable to be adopted in product optimization process [17]. Furthermore, Taguchi method had
been adopted by other researchers in the optimization of disc brake parameters in terms of
brake performance, which experimental results with higher accuracy and consistency had
been obtained [18]. Therefore, all of these had strongly pointed that Taguchi method was the
best suitable robust method to be adopted in this optimization research.

3. METHODOLOGY
3.1. Experimentation Planning
To perform research on optimization of disc brake parameters in terms of heat dissipation by
actual experimentation, Taguchi method had been used. A subject vehicle, Perodua Myvi 1.5
Special Edition (Automatic) had been chosen, which the actual disc brake rotor that installed
on the vehicle was the study subject. Three disc brake parameters that affected the heat
dissipation performance had been identified along with its respective factor values derived
from the minimum, average and maximum values. Table 1 showed the values that were
associated with each parameter respectively.

http://www.iaeme.com/IJMET/index.asp 46 editor@iaeme.com
 Ritesh Bhat and Kah Seng Lee

Table 1 Parameters of disc brake rotor that intended to be studied

Parameter Criteria Factor values
1 2 3
1 Number of rotor holes 12 18 24
2 Number of slots 0 3 6
3 Diameter of rotor holes (mm) 3 4 5
L9 orthogonal arrays in Taguchi method had been used to reduce the number of required
experiments. It divided the parameters and its respective factor values into nine different
randomise combination, which reduced greatly the number of required experiment
experimentss to nine
experiments instead of twenty-seven.
twenty Table 2 illustrates the experiment combinations resulted
from the orthogonal arrays.

Table 2 Experiments formed based on combination using L9 orthogonal array

Thus, total of nine experiments

experiments with randomise combination of factor values of
parameters had resulted to be performed. The disc brake rotor prototype samples that used in
the experimentation had been made by machining the original radial ventilation disc brake
rotor sample acc
according
ording to the combination that resulted.

3.2. Experimentation Procedure

rocedure
The experiment was started by rotating the disc brake rotor sample to the desired rotational
speed and temperature was checked with infrared temperature sensing gun. Then, the braking
leverr was applied for 60 seconds following by 10 seconds cooling time for five times
continuously.
The infrared temperature sensing gun was applied again to read the temperature reading
on the rotor surface after braking action. After the primary experiments, the optimum design
was being figured through the analysis of data by mean and signal-to signal to-noise
noise ratio. The
optimum
ptimum design was then undergoing the confirmation experiment to verify the results
accuracy.
The samples were being tested with the usage of customised
customised built disc
disc brake rotor testing
machine, which showed in Fig. 1. The disc brake rotor was rotated to the rotational speed that
approximately 550rpm, which equivalent to 60km/h for the respective vehicle in actual
travelling condition. After that, brake pad was actuated by push rod to rub on the brake rotor
surface to simulate the braking action of the vehicle. Due to the safety reasons, the braking
action was applied to slow down the rotor instead of stopping completely. Infrared
temperature gun had utilised
utilised to measure the temperature of disc brake rotor surface before and
after the braking process.

http://www.iaeme.com/IJMET/index.
http://www.iaeme.com/IJMET/index.asp
asp 47 editor@iaeme.com
 Optimization of the Brake Parameter for a Disc Brake System to Improve the Heat Dissipation
using Taguchi Method

Figure 1 Customised built disc brake rotor testing machine

Three fixed circumference points of the disc brake rotor ranging from 205±2mm,
185±2mm and 165±2mm were set to be the position to measure the temperature reading as the
temperature distribution on the surface was not uniform. The final results were in termed of
heating rate with the unit of °C/s, which smaller heating rate showed
showed better performance in
heat dissipation.

4. RESULTS AND DISCUSSIONS

DISCUSSIONS
4.1. Primary Experiments
xperiments
From the primary experimental results showed in Table 3, disc brake rotor sample with
eighteen 3mm diameter holes, six slots (P1-18,
(P1 P2--6, P3-3)
3) and twenty-four
twenty four 4mm diameter
holes, six slots (P1-24,
(P1 P2-6,
6, P3-4)
P3 4) having the maximum heat dissipation performance out of
others. Both had achieved the same results, 0.022°C/s,
0.022°C/s, which showed the highest heat
dissipation performance among the others.
It was also observed that single ventilation feature was not able to bring up the heat
dissipation performance effectively. Prototype sample with holes only ventilation featu
feature had
given the highest heating rate in the experiments.
Furthermore, all disc brake rotor prototypes that were modified by adding ventilation
features was performed better in terms of heat dissipation as the solid disc brake rotor resulted
the highest hheating
eating rate. The holes and slots served as passage for gases and dust to escape
during braking [3].
The experiment data did also notice that the temperature at inner circumference was the
highest and decreased when it came to the outer. This was due to the centrifugal force of the
disc brake rotor “threw out” most heat when rotating at high speed. The cold and fast moving
turbulent air was giving direct contact to the outer faces [19].

Table 3 Primary experimental results

http://www.iaeme.com/IJMET/index.
http://www.iaeme.com/IJMET/index.asp
asp 48 editor@iaeme.com
 Ritesh Bhat and Kah Seng Lee

Table 4 Mean of experiment data respectively to factor values

Level P1 P2 P3
1 0.040 0.043 0.031
2 0.035 0.032 0.035
3 0.029 0.028 0.056
Average 0.035 0.034 0.041
Table 4 showed the mean analysis calculated from the primary experimental results. The
third parameter had the highest average mean among the other two parameters, which mean it
was the parameter that giving the least performance in heat dissipation. More heat had
retained on the surface as the hole diameter increased.
On the other hand, the number of slots had the least effect on heat retaining as resulted the
least value in the average mean. Increasing of slot number had lowered the heating rate, which
indirectly improved the heat dissipation performance. Hence, disc brake rotor design with less
number of holes, less number of slots and larger diameter of holes ranked the least in heat
dissipation performance.
From the mean analysis, it concluded that disc brake rotor prototype with twenty-four
4mm diameter holes, six slots (P1-24, P2-6, P3-4) was the optimum design. Disc brake rotor
with eighteen 3mm diameter holes, six slots (P1-18, P2-6, P3-3) was not selected as optimum
design due to the diameter of rotor holes contributed the least in heat dissipation.

4.2. Signal-to-Noise Ratio

The smaller-the-better quality characteristics in analysis of the signal-to-noise ratio was used
for this experimental results. The minimum the heating rate was the expectation that should be
obtained at the end to find out the optimum design and most effective parameter that could
maximize the heat dissipation. The formula given in the Taguchi method:-
Ʃ
ƞ = −10 log (1)
Where Yi was the result obtained with respect to ith number of experiment, n was the
number of experiment and N was the total number of experiments, was used to calculate the
signal-to-noise ratio. Table 5 and Fig. 2 illustrated the signal-to-noise ratio of experimental
results and its plotted graph respectively.

Table 5 Signal-to-noise ratio of experimental results

Level P1 P2 P3
1 28.00 27.35 29.83
2 28.81 29.77 28.74
3 30.56 30.54 28.53
Delta 2.56 3.19 1.30
Rank 2 1 3
Percentage (%) 36.31 45.25 18.44

http://www.iaeme.com/IJMET/index.asp 49 editor@iaeme.com
 Optimization of the Brake Parameter for a Disc Brake System to Improve the Heat Dissipation
using Taguchi Method

Figure 2 Graphs of signal-to

signal to-noise
noise ratio versus factor values level respectively to parameters
The smaller
smaller-the
the-better
better quality characteristics had brought the meaning stated that better
heat dissipation performance was associated with higher value in signal-signal-to-noise
noise ratio. The
number of slots (P2) was having the highest value, which ranked the first place in heat
dissipation performance. The slot ventilation feature in the disc brake rotor design acted as the
channel that enhanced the effect of centrifugal force that “threw away” the heat during
rotating. The number of rotor holes ranked the second wh while
ile the diameter of rotor holes
ranked the least in heat dissipation performance. This mean
meant that enlarging of ventilation hole
did not pr
provide an effective influence on the heat transfer of disc brake rotor.
In overall, all data pointed that disc brake rotor
rotor prototype sample with twenty
twenty-four
four 4mm
diameter holes, six slots (P1-24,
(P1 P2-6,
6, P3-4)
P3 4) was the optimum design out of all nine
combinations and number of slots was the most significant parameter. This analysis had
matched and confirmed the results that obtained
obtained from the mean analysis. Therefore, the
optimum design had been carried on with confirmation experiment for results verification.

4.3. Confirmation Experiment

xperiment
The optimum design of disc brake rotor prototype sample with twenty-four
twenty four 4mm diameter
holes and six slots (P1-24,
(P1 24, P2-6,
P2 P3-4) 4) had been further verified through the confirmation
experiment, which recommended in Taguchi method to verify the experiment data. Table 6
showed the experimental results obtained from the confirmation experiment.

Table 6 Confirmation experiment result

The optimum design of the disc brake rotor did show a great result in heat dissip
dissipation
performance. Less than 5% of result difference between the predicted result and actual
experimental result was obtained, which proved the data accuracy and the effectiveness of the
Taguchi method. Data obtained through the experiments had been verifi
verified
ed and confirmed.
Also, disc brake rotor with twenty-four
twenty four 4mm diameter rotor holes and six ventilation slots
(P1-24,
24, P2
P2-6, P3-4)
4) had been confirmed as the optimum design to improve heat dissipation
performance through the confirmation experiment.

http://www.iaeme.com/IJMET/index.
http://www.iaeme.com/IJMET/index.asp
asp 50 editor@iaeme.com
 Ritesh Bhat and Kah Seng Lee

5. CONCLUSIONS
The testing rig was successfully stimulated the vehicle braking process and differentiate
clearly on heat dissipation performance of each prototype sample. Optimum ventilation
design and most significant parameter in heat dissipation performance for disc brake rotor had
successfully been identified through the experiments by using the testing rig.
It was proved that disc brake rotor with twenty-four 4mm diameter holes and six slots
(P1-24, P2-6, P3-4) was the optimum design with heating rate as low as 0.022°C/s.
In addition, number of slots gave an effect at the rate of 45.25% in enhancing of heat
dissipation performance in disc brake rotor followed by number of rotor holes and diameter of
rotor holes that at the rate of 36.31% and 18.44% respectively. All in all, the research had
been completed successfully with effective used of Taguchi method in obtaining of optimum
design as well as most efficient parameter in heat dissipation performance of disc brake rotor.

REFERENCES
[1] Reif, K. (2014). Brakes, Brake Control and Driver Assistance Systems: Function, Regulation
and Components. Germany: Springer Vieweg.
[2] Elangovan, P., & Anas, O. V. (2016). Problems Associated With Existing Disc Brake Rotors
and Suggestion of Alternate Ways. International Journal of Innovative Science, Engineering &
Technology (IJISET), 3(12), 198–200.
[3] Anto, A. J., Nair, A. K., & P, A. (2016). Comparative Analysis of Disc Brake Rotors Using
FEA. Internationl Journal for Research in Applied Science & Engineering Technology
(IJRASET), 4(III), 1015–1026.
[4] Nikam, H., Mishra, P., & Bharambe, S. (2014). Design and Analysis of Brake Rotor with
Parameter Optimization. International Journal of Automobile Engineering Research and
Development (IJAuERD), 4(4), 21–30. Retrieved from
[5] Duzgun, M. (2012). Investigation of Thermo-Structural Behaviors of Different Ventilation
Applications on Brake Discs. Journal of Mechanical Science and Technology, 26(1), 235–240.
[6] Antanaitis, D., & Rifici, A. (2006). The Effect of Rotor Cross drilling on Brake Performance.
SAE International Technical Paper 2006-01-0691.
[7] Rathod, N. (n.d.). Design, Optimization and Analysis of Brake Disc by Using FEA Method.
International Journal for Advance Research in Science and Engineering.
[8] Yan, H. B., Feng, S. S., Yang, X. H., & Lu, T. J. (2015). Role of Cross-Drilled Holes in
Enhanced Cooling of Ventilated Brake Discs. Applied Thermal Engineering, 91, 318–333.
[9] Sowjanya, K., & Suresh, S. (2013). Structural Analysis of Disc Brake Rotor. International
Journal of Computer Trends and Technology (IJCTT), 4(7), 2295–2298.
[10] Prasad, S. D. S., & Kumar, K. S. (2015). Design and Analysis of Drilled Rotar of a Disc Brake
1. International Journal of Eminent Engineering Technologies, 3(2).
[11] Kevorkijan, V. (2003). Engineering Wear-Resistant Surfaces in Automotive Aluminum. JOM,
55, 32–34.
[12] Huang, M.-L., Hung, Y.-H., & Yang, Z.-S. (2016). Validation of a Method Using Taguchi,
Response Surface, Neural Network, and Genetic Algorithm. Measurement, 94, 284–294.
[13] Anderson, M. J., & Whitcomb, P. j. (2010). Design of Experiments. In Kirk-Othmer
Encyclopedia of Chemical Technology (pp. 1–22).
[14] Karna, S. K., & Sahai, R. D. (2012). An Overview on Taguchi Method. International Journal
of Engineering and Mathematical Sciences, 1, 11–17.

http://www.iaeme.com/IJMET/index.asp 51 editor@iaeme.com
 Optimization of the Brake Parameter for a Disc Brake System to Improve the Heat Dissipation
using Taguchi Method

[15] Antony, J., Perry, D., Wang, C., & Kumar, M. (2006). An Application of Taguchi Method of
Experimental Design for New Product Design and Development Process. Assembly
Automation, 26(1), 18–24.
[16] Taguchi, G. (1993). Taguchi on Robust Technology Development: Bringing Quality
Engineering Upstream. (K. M. Ragsdell, Ed.)Journal of Pressure Vessel Technology (Vol.
115). New York: The American Society of Mechanical Engineers.
[17] Antony, J. (2006). Taguchi or Classical Design of Experiments: A Perspective From a
Practitioner. Sensor Review, 26(3), 227–230.
[18] Ghazaly, N. M., Makrahy, M. M., Mahmoud, K. R., Abd El-Gwwad, K. A., & Abd-El-
Tawwab, A. M. (2013). Optimization of a New Wedge Disc Brake Using Taguchi Approach.
International Journal of Mechanical Engineering, 3(11). Retrieved from
[19] Voller, G. P., Tirovic, M., Morris, R., & Gibbens, P. (2003). Analysis of Automotive Disc
Brake Cooling Characteristics. Proceedings of the Institution of Mechanical Engineers, Part D:
Journal of Automobile Engineering, 217, 657–666.
[20] V. Saritha and Vinayak G. Kachare, Finite Element Analysis of Disc Brake Rotor Using
Different Materials. International Journal of Mechanical Engineering and Technology, 7(6),
2016, pp. 410–416.
[21] R. Ramesh Kumar and V. Thiruvengadam and J. Thamilarasan. Manufacturing and Force
Determination of Composite Disc Brake. International Journal of Mechanical Engineering and
Technology, 8(2), 2017, pp. 246–255

http://www.iaeme.com/IJMET/index.asp 52 editor@iaeme.com

View publication stats