DESIGN AND

OPTIMIZATION OF
DISC BRAKE
 ABSTRACT
• The disc brake is a device for slowing or stopping the rotation of a wheel. Repetitive braking
of the vehicle leads to heat generation during each braking event.
• Transient Thermal and Structural Analysis of the Rotor Disc of Disk Brake is aimed at
evaluating the performance of disc brake rotor of a car under severe braking conditions and
there by assist in disc rotor design and analysis. Disc brake model and analysis is done using
ANSYS workbench 14.5.
• The main purpose of this study is to analysis the thermo mechanical behavior of the dry
contact of the brake disc during the braking phase. The coupled thermal-structural analysis is
used to determine the deformation and the Von Mises stress established in the disc for the both
solid and ventilated disc with two different materials to enhance performance of the rotor disc.
• A comparison between analytical and results obtained from FEM is done and all the values
obtained from the analysis are less than their allowable values. Hence best suitable design,
material and rotor disc is suggested based on the performance, strength and rigidity criteria.
 INTRODUCTION
• The disc brake is a device for slowing or stopping the rotation of a wheel. A brake
disc usually made of cast iron or ceramic composites includes carbon, Kevlar and
silica, is connected to the wheel and the axle, to stop the wheel. A friction material in
the form of brake pads is forced mechanically, hydraulically, pneumatically or
electromagnetically against both sides of the disc.
• A friction brake generates frictional forces as two or more surfaces rub against each
other, to reduce movement. Based on the design configurations, vehicle friction
brakes can be grouped into drum and disc brakes.
• If brake disc are in solid body the heat transfer rate is low. Time taken for cooling
the disc is low. If brake disc are in solid body, the area of contact between disc and
pads are more.
• Braking system is one of the important safety components of a vehicle. It is mainly
used to decelerate vehicles from an initial speed to a given speed. A friction based
braking system is a common device to convert kinetic energy into thermal energy
through a friction between the brake pads and the rotor faces. Because high
temperatures can lead to overheating of the brake fluid, seals and other components,
the stopping capability of a brake increases with the rate at which heat is dissipated
due to forced convection and thermal capacity of the system.
• A disc brake is a type of brake that uses calipers to squeeze pairs of pads against a disc
or "rotor" to create friction. This action retards the rotation of a shaft, such as
a vehicle axle, either to reduce its rotational speed or to hold it stationary. The energy
of motion is converted into waste heat which must be dispersed.
• Hydraulically actuated disc brakes are the most commonly used form of brake for
motor vehicles, but the principles of a disc brake are applicable to almost any rotating
shaft.
 LITERATURE SURVEY
• Structural and Thermal Analysis of Rotor Disc of Disc
Brake Manjunath T V1, Dr Suresh P M
Transient Thermal and Structural Analysis of the Rotor Disc of
Disk Brake is aimed at evaluating the performance of disc
brake rotor of a car under severe braking conditions and there
by assist in disc rotor design and analysis.

• Thermal analysis of both ventilated and full disc brake

rotors with frictional heat generation A. Belhocinea, C.-D.
Chob, M. Noubyc, Y. B. Yi d, A. R. Abu Bakare
The objective of this work is to investigate and analyze the
temperature distribution of rotor disc during braking operation
using ANSYS Multiphysics.
 LITERATURE SURVEY
• Thermal Stress Analysis of Automotive Disc Brakes by
Saiprasit Koctniyom
The main function of a foundation brake is to generate a
retarding torque by converting mechanical energy to thermal
energy by virtue of the frictional work done in relative sliding
at the rotor-pad interface.

• Thermal Analysis Of Disk Brake In Order To Study The

Brake Fluid Vaporization Phenomenon Of A Formula Sae
Car By Anurag Dey
The study was concentrated on finding the heat partition
towards the brake disk and brake pads when brakes are applied.
 PROBLEM DEFINATION

High stresses are seen in brake disk due to friction

between caliber and disk due to braking operation. This
results into wear of brake disc and calipers. So to avoid
this wear this disc brake is designed and optimization is
carried on it.
 OBJECTIVE
• To determine the thermal stresses.
• To optimize the weight of the disk brake.
• To reduce the stress values.
• To measure the temperature using non contact type thermal
gun.
 OVERVIEW
Requirement:
 Static structural and steady state thermal analysis of disc brake.
 Optimization of disc brake.
 Stress plots.
 Deformation plots.
 Temperature plots.
Technology:
 CATIA V5 R20 for Solid Modeling.

Ansys 17.0 for Finite element modeling and Analysis.
Summary
To carry out Static Structural Stress & Steady State Thermal Analysis and
Topological Optimization of Disc brake.

Situation
To verify stress generated in the disc brake for load case.

Loadings:
Pressure is applied as per disc brake working.
 WORKING
• Modeling the disc brake.
• Performing Finite Element Modeling.
• Applying Boundary and Loading conditions.
• Solving the FE Model for results.
 METHODOLOGY
• Step 1:- We started the work of this project with literature survey. We gathered many research
papers which are relevant to this topic. After going through these papers we learnt about Disc
Brake Optimization.
• Step2:- After that the components which are required for our project are decided.
• Step 3:- After deciding the components, the 3 D Model and drafting will be done with the
help of CATIA software.
• Step 4:- The Analysis of the components will be done with the help of ANSYS using FEA.
• Step 5:- Comparative analysis of Reaction forces will be made between simulation results
and then Results and conclusions will be drawn.
 REFERENCES
• Structural and Thermal Analysis of Rotor Disc of Disc Brake Manjunath T V1,
Dr Suresh P M 
• Thermal analysis of both ventilated and full disc brake rotors with frictional heat
generation A. Belhocinea, C.-D. Chob, M. Noubyc, Y. B. Yi d, A. R. Abu Bakare 
• Thermal Stress Analysis of Automotive Disc Brakes by SaiprasitKoctniyom 
• Thermal Analysis Of Disk Brake In Order To Study The Brake Fluid
Vaporization Phenomenon Of A Formula Sae Car By Anurag Dey 
• Structural and Thermal Analysis of Brake Disc Viraj Parab, Kunal Naik, Prof A.
D. Dhale 
• Structural And Thermal Analysis Of Disc Brake Using Solidworks And Ansys By
Rakesh Jaiswal, Anupam Raj Jha, Anush Karki, Debayan Das, Pawan Jaiswal,
Saurav Rajgadia and Ankit Basnet