The document discusses the design, analysis, and optimization of a disc brake rotor for a Bajaj Pulsar 150 motorcycle using finite element analysis. It summarizes the existing ventilated disc brake rotor design and proposes a new slotted design with holes. Both designs are modeled in CATIA and analyzed in ANSYS for static structural stresses and transient thermal performance using various materials. The analysis aims to determine the material that provides the best performance for the proposed design based on von Mises stresses, heat dissipation, and deformation.

1. Design , Analysis and Optimization
of Pulsar 150’s Disc Brake Rotor
using Finite Element Method

2. Agenda
Abstract Briefing on Brakes
Methodology Calculations
Analysis and
Results
Conclusion

3. Abstract
The main objective is to propose a new automotive brake disc rotor design
for BAJAJ PULSAR 150 in order to the total deformation and increase the
maximum heat dissipation. Ventilated disc (existing) and Slotted with holes
disc (proposed) are designed in CATIA V5 R20. The static structural analysis
and transient thermal analysis of brake disc rotor is done using ANSYS 16.2 ,
which is a dedicated finite element package used for determining the
temperature distribution, variation of the stresses and deformation across
the disc brake profile. Here, 5 materials are attributed to the proposed
design. The best of the materials for the proposed design of brake disc rotor
is to be suggested based on the magnitude of von - misses stresses, shear
stress, strain deformation, total heat flux.

4. Introduction to Brakes
A brake is a mechanical device that uses frictional resistance to retard a
motion by absorbing kinetic energy from and convert it into heat
energy. The disc brake is a type of braking system that uses a disc rotor
is connected to the axle of wheel and a set of friction material called as
brake pads (mounted on a component called brake caliper) is forced
usually by hydraulic pressure against both sides of disc which causes it
to stop with the help of friction.

5. Working Principle
• When a certain amount of force is applied on the brake lever or pedal, the
push rod which is connected through the lever or pedal to master cylinder
piston transmits the force to it, this movement allows the master cylinder
piston to slide and push the return spring inside the bore of the master
cylinder which generates pressure in the reservoir tank to flow over it into
the brake hosepipes.
• A secondary seal ensures that the brake fluid from escaping to another side.
Then the fluid enters into cylinder bore of caliper assembly via brake
hosepipes and pushes the caliper piston or multiple pistons, at this time the
piston ring rolls with the piston, then the caliper piston pushes brake pad.
• This movement causes brake pads to apply force on the brake disc which
creates friction force and opposes the rotational motion of the brake
disc/rotor. In this way, a disc brake system contributes to stop or slow down a
vehicle.

6. Types of Brakes
Friction brakes are the most commonly employed braking system in commercial or
special purpose vehicles. They generally are rotating devices with a rotating wear
surface like Disc or drum and a stationary pad or a shoe. Here, the kinetic energy of
the moving vehicle is utilized to stop the vehicle by conversion of this kinetic energy
into heat energy/frictional energy . A few common configurations of this type of
braking are disc brakes, drum brakes and hydrodynamic brakes.
1. Disc Brake
2. Drum Brake
3. Electromagnetic Brake

7. Disc Brakes
Shoes or pads contract and provide
compressive frictional force on the outer
surface of a rotating Disc. It is a circular
metal Disc on which the pads are mounted.
Usually, it is made up of cast iron material.
The design of Disc brakes is varied
depending on the application, amount of
exposure, thermal properties of the
material and the amount of heat dissipation
required when brakes are applied and the
total mass to be stopped . This project
report will contain the design of a Disc brake
rotor, and analyze results of Structural and
Thermal Analysis at a later stage

8. Drum brakes
Shoes or lining expand and rub against the
inside surface of a rotating drum. Drum is
again made up of cast iron material and
mounted in the wheel hub in such a manner
that the liner pads attach themselves to the
inner surface of the drum and during the
braking process, the shoe or brake lining
expand or move outwards, due to the cam and
spring action, to attach themselves to the
brake drum which provides friction and causes
the drum to retard or stop its rotating motion.
Drums are usually heavier than Disc brakes and
occupy significantly more space due the lining
and drum it and hence its application in
commercial vehicles is somewhat restricted.

9. Electromagnetic Brakes
Electromagnetic brakes are also called
electro-mechanical brakes or EM brakes. They
slow or stop motion using electromagnetic
force .An electrical current goes through a
coil on the brake to create a magnetic field
strong enough to move an armature on or off
a magnetic face. Electromagnetic brakes have
a wide variety of uses in the locomotive
industry, particularly for trains and trams. In
the early twentieth century, trains and trams
used electromagnetic brakes to ensure their
tracks' safety and efficiency. They were widely
used as emergency braking systems

10. Components of Disc Brake System
1. WHEEL HUB ASSEMBLY- It holds the wheel and the
disc rotor and bearing inside it allows their smooth
rotation.
2. DISC BRAKE ROTOR- It is the part to which the brakes
pads squeeze against which retard the rotation of
the wheel. It produces a lot of heat due to friction
and the drilled holes provides ventilation to remove
this heat.
3. BRAKE CALIPER ASSEMBLY-It uses the hydraulic
forces from the brake pedal to squeeze the brake
pads to the rotor surfaces, thus creating friction and
decelerates the wheel. The caliper assembly consist
of:
• Caliper Bracket
• Slider Pins
• Dust boots/ Rubber
Bellows
• Inner brake pads
• Outer Brake Pad
• Caliper Frame
• Piston
• wheel

12. Components of Disc Brake System
1. WHEEL HUB ASSEMBLY- It holds the wheel and the
disc rotor and bearing inside it allows their smooth
rotation.
2. DISC BRAKE ROTOR- It is the part to which the brakes
pads squeeze against which retard the rotation of
the wheel. It produces a lot of heat due to friction
and the drilled holes provides ventilation to remove
this heat.
3. BRAKE CALIPER ASSEMBLY-It uses the hydraulic
forces from the brake pedal to squeeze the brake
pads to the rotor surfaces, thus creating friction and
decelerates the wheel. The caliper assembly consist
of:
• Caliper Bracket
• Slider Pins
• Dust boots/ Rubber
Bellows
• Inner brake pads
• Outer Brake Pad
• Caliper Frame
• Piston
• wheel

13. Methodology
The approach to this project has been through the following segments:
A. Design of Existing Model and Proposed : The existing model of brake disc rotor
is designed based on analytical measurements and standard values available from a
standard website. The standard brake disc rotor that we consider here is from BAJAJ
PULSAR 150. The brake disc rotor of BAJAJ PULSAR 150 and proposed model are
designed using CATIA V5 R20.
B. Calculations : To make the calculation perfect the initial condition are taken
from dealer site and the relevant assumptions are made
C. Analysis of Models : Static and thermal analysis on the existing model has been
performed using existing model using Ansys 16.2 .
D. Conclusion : Based off of the analytical data available ,finally, we conclude the
suitable materials of the proposed disc rotor design from these materials Grey cast
iron, Alsic, Ti6AL4V, AISI 6150, EN8.

14. Material Properties

15. CALCULATIONS
Initial conditions and assumptions To make the
calculation perfect the initial condition are taken from
dealer site and the relevant assumptions are made as
follows
The total weight of the vehicle is assumed to be 300
Kg.
The vehicle is assumed to travel at a maximum speed
of 100kmph, i.e.,v= 27.77m/s
The axial weight distribution is taken as 0.5
The coefficient of friction is assumed to be 0.5
The effective radius is taken as, R eff = 0.12 m

16. • The Kinetic energy to absorbed is taken as 0.9 J
• The standard hydraulic pressure is taken as 1 Mpa
• The coefficient of friction is same for brake pad
and rotor, i.e., µI = µO.
• The ambient temperature is taken as 23 °c
• The vehicle is said to stop using 1 brake caliper,
i.e., the stopping distance is taken as 50 m
• The brake pad's total coverage angle is measured
to be 42.5°
• The vehicle has varying leverage and actuation
based on driving condition so, a FOS of 2.5 is
taken into consideration for single stop surface
temperature rise.

17. BOUNDARY CONDITIONS
• 6 inner bolt holes - FIXED
• brake torque - 120 N-m
• Tangential force - 1000 N (applied using brake pads)
• brake pad displacement - 0,0,free
• mesh – Tetrahedral

18. DESIGN PROCEDURE OF DISC ROTOR IN CATIA WORKBENCH- EXISTING DESIGN-NORMAL DISC

19. DESIGN PROCEDURE OF DISC ROTOR IN CATIA WORKBENCH
PROPOSED DESIGN-SLOTED VENTILATED WITH NORMAL HOELS

20. STEPS INVOLVED IN STATIC AND THERMAL ANALYSIS
• Structured part in CATIA V5 workbench after brought into ANSYS
workbench presently select the consistent state warm
Examination.
• ENGINEEERING MATERIALS (MATERIAL PROPERTIES).
• IMPORT GEOMENTRY.
• MODEL (GENERATES NODES AND ELEMENTS).
• SET UP (BOUNDARY CONDITIONS).
• SOLUTION
• RESULT.
PRE-PROCESSOR - SOLUTION - POST PROCESSOR

21. MESH AND BOUNDARY CONDITIONS
EXISTING DESIGN-NORMAL DISC
MESH:NODES: ELEMENTS: BOUNDARY CONDITIONS

22. MESH AND BOUNDARY CONDITIONS OF PROPOSED
DESIGN- SLOTTED DISC WITH HOLES BRAKE
ROTOR
Nodes:61813, Elements:23205 Force:1000N, Moment: 120 N-m

23. RESULTS AND DISCUSSIONS
Perform the static and thermal analysis with two design and various
materials Grey cast iron, Alsic, Ti6AL4V, AISI 6150, EN8 After formulation of
the heat flux thermal boundary conditions they are applied on the FE model
to obtain an estimate of the temperature distribution in the disc rotor. The
thermal boundary conditions on the rotor are as follows Initial temperature
on the rotor is set to 250C.Convection is applied on those surfaces of rotor
which is not in contact with the pad, with the film coefficient of
0.0025w/mm2 Heat flux at each second time steps is applied on the
respective contact region.
The pressure values are applied for the disc / rotor is 1000N. The hub region
of the rotor is constrained in all degree of freedom. Consider the moment is
120N-m, Clock wise direction.

24. ALSI 6150 MATERIAL-EXISTING DESIGN
Total heat flux of AISI 6150 Material
Strain of AISI 6150 Material
Shear stress of AISI 6150 Material
Total deformation of AISI 6150 Material
Von-misses stress of AISI 6150 Material

25. ALSIC MATERIAL
Total heat flux of Alsic Material
Strain of Alsic Material
Shear stress of Alsic Material
Total deformation of Alsic Material
Von-misses stress of Alsic Material

26. ALSI 6150 PROPOSED DESIGN
Total heat flux of AISI 6150 Material
Strain of AISI 6150 Material
Shear stress of AISI 6150 Material
Total deformation of AISI 6150 Material
Von-misses stress of AISI 6150 Material

27. ALSIC MATERIAL
Total heat flux of Alsic Material
Strain of Alsic Material
Shear stress of Alsic Material
Total deformation of Alsic Material
Von-misses stress of Alsic Material

28. TI-6AL-4V MATERIAL
Total heat flux of TI-6AL-4V Material
Strain of TI-6AL-4V Material
Shear stress of TI-6AL-4V Material
Total deformation of TI-6AL-4V Material
Von-misses stress of TI-6AL-4V Material

29. The static structural analysis of Grey cast iron, Alsic, Ti6AL4V, AISI 6150, EN8 are done we are taking load conditions
are Fixed at holes and apply load at disc pad and results are obtained for Equivalent (Von-Mises) stress, shear stress,
strain total deformation and Heat flux These results are plotted graphically and a comparison is made between
these results.
we can observe that in case of equivalent (von-misses) stress, disc rotor made of Two
designs and various materials Grey cast iron, Alsic, Ti6AL4V, AISI 6150, EN8 finally
AISI 6150 is found to has the least stress of 242.11MPa as shown below figure.
263.73
252.36
248.33
253.79
256.39
251.59
247.53
242.11
248.88
250.24
230
235
240
245
250
255
260
265
270
Grey Cast Iron EN 8 AISI 6150 TI6AL4V AISIC
Von-Misses Stress (in MPa)
Von-misses stress(MPa)-Existing Design-Drilled Disc Brake Rotor
Von-misses stress(MPa)-Proposed Design-Cross Drilled with Slotted Holes Disc Brake Rotor

30. we can observe that in case of Total deformation disc rotor made of Two designs and
with analysis various materials Grey cast iron, AlSic, Ti6AL4V, AISI 6150, EN8 finally
AISI 6150 is found to have total deformation of cross drilled with slotted driller rotor
have 0.202 mm as shown below graph
0.417
0.233
0.2076
0.288
0.392
0.25603
0.2115 0.2021
0.2229
0.2533
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
Grey Cast Iron EN 8 AISI 6150 Ti6AL4V AlSiC
Total Deformation(in mm)
Total Deformation(in mm)-Existing Design-Drilled Disc Brake Rotor
Total Deformation(in mm)-Proposed Design-Cross Drilled with Slotted Holes Disc Brake Rotor

31. we can observe that in case of shear stress disc rotor made of Two designs and with
analysis various materials Grey cast iron, Alsic, Ti6AL4V, AISI 6150, EN8 finally AISI
6150 is found to least shear stress of cross drilled with slotted driller rotor have
64.99Mpa as shown below graph
70.67
67.466
65.752
67.466
68.298
68.49
66.499
64.499
66.233
67.605
61
62
63
64
65
66
67
68
69
70
71
72
Grey Cast Iron EN 8 AISI 6150 TI6AL4V AlSiC
Shear Stress (MPa)
Shear Stress(MPa)-Existing Design-Drilled Disc Brake Rotor
Shear Stress(MPa)-Proposed Design-Cross Drilled with Slotted Holes Disc Brake Rotor

32. we can observe that in case of strain disc rotor made of Two designs and with analysis
various materials Grey cast iron, Alsic, Ti6AL4V, AISI 6150, EN8 finally AISI 6150 is
found to least strain of cross drilled with slotted driller rotor have 0.00124 as shown
below graph
0.00233
0.00134
0.00125
0.00137
0.00233
0.00133 0.00131
0.00124
0.00132 0.00132
0
0.0005
0.001
0.0015
0.002
0.0025
Grey Cast Iron EN 8 AISI 6150 Ti6AL4V AlSiC
Strain
Strain -Existing Design-Drilled Disc Brake Rotor
Strain-Proposed Design-Cross Drilled with Slotted Holes Disc Brake Rotor

33. We can observe that in case of Total heat flux disc rotor made of Two designs and with
analysis various materials Grey cast iron, Alsic, Ti6AL4V, AISI 6150, EN8 finally AISI
6150 is found to Highest heat transfer least shear stress of cross drilled with slotted
driller rotor have 2.7461 W/mm2as shown below graph
1.61
2.421
2.0117
0.675
3.674
3.2284 3.2284
2.7461
0.7427
7.9873
0
1
2
3
4
5
6
7
8
9
Grey Cast Iron EN 8 AISI 6150 Ti6AL4V AlSiC
Total Heat Flux(W/mm^2)
Total Heat Flux(in W/mm^2)-Existing Design-Drilled Disc Brake Rotor
Total Heat Flux(in W/mm^2)-Proposed Design-Cross Drilled with Slotted Holes Disc Brake Rotor

34. CONCLUSION
Design and analysis are done perform the static and thermal analysis This
project work has provided an excellent opportunity and experience, to use
limited knowledge. It help to gain a lot of practical knowledge regarding planning
and implementing while doing this project work. The work is a good solution to
bridge the gates between institution and industries. The work is completed with
the limited time successfully. The figures and graphs which are shown above
reveals the stress, strain, shear stress, Total deformation, thermal stress, of the
disc brake rotor with Grey cast iron, Alsic, Ti6AL4V, AISI 6150, EN8 Materials.
From all materials which are taken into consideration, AISI 6150 show the best
material desirable results for disc brake rotor (vented with cross-drilled holes)
because of Less stress, deformation, shear stress, strain and better heat transfer
rate .so it is suitable for manufacturing purpose .This is important to understand
action force and friction force on the disc brake new material, which use disc
brake works more efficiently, which can help to reduce the accident that may
happen in each day.

35. LITERATURE REVIEW
1. T. D. Gillespie A book of Fundamentals of Vehicle Dynamics an overall guide to design a
automobile used for the better understanding of braking system, its performance
improvements and for braking calculation. It covers from the very basic coordinating system,
acceleration performance system, braking performance, road loads, ride, suspension, tires.
2. R. Limpert, A book of Brake Design and Safety purely guide of brake fundamentals, braking
systems, automatic brake control, analysis design and analysis of friction brakes helps us to
revise our concepts and correct our mistakes. Calculation of braking system was done on the
basis of the book.
3. BAJA SAEINDIA Rulebook 2018, as it mentioned a disc rotor developed fully from the zero basis
using the product development steps, disc was tested as a part of BAJA ATV- All terrain
vehicle braking system under critical limits and achieved the target constraints. Rulebook, a
set of every minute data being used to design the whole vehicle and guides thoroughly.
4. S. R. Abhang and D. P. Bhaskar, Associate Professor Department of Mechanical Engineering,
SRES College of Engineering, Pune University, Kopargaon, India, discusses the problems
occurs in brake system during braking like Squealing, scarring, excessive rusting, cracking. It
helps us to give a whole of braking calculation with the proper assembly of braking system
and assumed data makes a calculation of forces generated torque at pads, net heat flux and
other parameters. Use of ANSYS was also done to mesh the disc and thermal analysis was
performed to get the real time view of disc under circumstances.

36. 5. Y.H. Mishra, V. R. Deulgaonkar and P. A. Makasre works at JCOE Kuran, starts with a
overview how technology changing the world today and brief about disc brake
rotor system assembly and describes about material selection for disc brake rotor
among comparison of steel, aluminium and its alloy like magnesium, titanium. It
helps us to choose us the best suitable material under current scenario
considering our object of work. An assumed data was used to calculate working
force, stress, torque generated, brake distance and its calculation. Use of wide
ranging calculation was done to understand the braking phenomenon and for
comparison.
6.A. Maleque, S. Dyuti and M. M. Rahman from Department of Manufacturing and
Materials Engineering, International Islamic University Malaysia, Kuala Lumpur,
Malaysia has a wide research on material selection through exhaustive method
and comparative analysis starts with steps of material selection chooses six
materials into consideration and provides using Digital Logic Method (DLM) assigns
numbers using product- process matrix.
7. P. kllungchang, P. Deshattiwar, K. Menjo, Ruikar, S. Kumar, R. K. Shrivastava from
department of mechanical engineering presents a thermal analysis of brake disc
comparatively same work as ours. Design aspects used for braking calculation and
also to better understand finite element analysis and ANSYS. It describes about
material selection, FEA limitations and advantages and thermal analysis of brake
disc through iterations.
8. J. Rakesh, A. Raj, K. Anush, D. Debayan, J. Pawan, R. Saurav fromDepartment of
Mechanical Engineering, NIT Durgapur presents Structural and Thermal Analysis of
Disc Brake using Solidworks with a objective of calculating values of shear stress,
total deformation, convective heat transfer coefficient and temperature
distribution on disc brake. It presents structural and thermal analysis of disc brake
rotor using FEA, CAD and ANSYS and shows the variation of time with respect of
time. A proper calculation has been done using available data.

37. THANK YOU