OCTOBER 19-20, 2012 - YMCA University of Science & Technology

Proceedings of the National Conference on
Trends and Advances in Mechanical Engineering,
YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012
Deflection and stress Analysis of Brake Disc using Finite Element Method
Atul sharma 1 and M.L. Aggarwal 2
1 Sr. Instructor, Machine shop, YMCAUST, Faridabad-121006,India.
E-mail: atulfbd@rediffmail.com
2 Professor. Mech. Engg. Deptt, YMCAUST, Faridabad-121006,India.
aggarwalmlal@rediffmail.com
Abstract
Disc brake are often used in automobile transmission system to stop moving machine. Due to space constraint
and performance requirement, disc brakes have fluctuating load characteristics, resulting in local stress and
deflections. Friction temperature in brake disc can cause material carbonization and debonding. This research
paper explains the design and finite element analysis (FEA) model of brake disc by which deflections in X, Y, Z
direction and Von mises stress can be calculated by applying boundry conditions. The FEA outcomes are
correlated with experimental data. A good agreement, with 5% discrepancy in the experimental data during the
first engagement is obtained. The developed method improves the understanding of the structural failure, modal
prediction, operating conditions, and reduces product development time and cost.
1. Introduction
The disc brake is a device for slowing or stopping the rotation of a wheel while it is in motion. To stop the
wheel, friction material in the form of brake pads is forced against both sides of the disc. The metallurgical
properties of a rotor determine its strength, noise, wear and braking characteristics. Joe Y.G. cha [1] explained
Analysis of disc brake instability due to friction induced vibration. M.Bayat[2] explained the effect of ceramic in
combination of functionally graded rotating disc and the friction-induced vibration with a constant friction
coefficient. Utz von wagner[3] explained Influence of dynamic brake pad properties on automotive disc brake
squeal. A linear, lumped, and distributed parameter model to represent the floating caliper disc brake system. For
actual geometric approximation, the disc is modeled as a hat-disc shape structure by the finite element method.
Computer Aided Engineering is Computer Aided technology for supporting engineers in tasks such as analysis,
simulation, design, manufacture, planning, diagnosis and repair. Computer Aided Analysis (CAA) is a technique
by which approximate solution of a numerical problem can carry out. ANSYS is known as the standard in the
field of Computer Aided Engineering. Finite Element method (FEM) simulates a physical part or assembly’s
behavior by dividing the geometry of the part into a number of elements of standard shapes, applying loads and
constraints, then calculating deflection and stresses.
The stress and deflections is pointed out as essential parameter by most of the researchers in the case of brake
disc and advanced softwares are available for doing the analysis.
Experimentally testing the brake disc takes lot of time. The objective of present work is to reduce brake disc
testing time using computer model.
2. Experimentation
Computer aided engineering analysis of brake disk is a process in which two dimensional drawing is prepared on
Autocad followed by solid modeling and then finite element analysis by meshing. The meshed model divided
into the element list assigned with material properties. Boundry conditions are applied on model and deflections
in X,Y,Z directions along with von Mises stresses are calculated. The procedure for static analysis consists of
these main steps Building the model, Obtaining the solution, Reviewing the results.
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