1. The document presents a case study on stress analysis of a disc brake rotor in a static condition. It aims to optimize the design of a disc brake rotor for a 220cc Bajaj motorcycle. 2. The study models different slot shapes for the rotor in CATIA and analyzes them in ANSYS to determine stress levels, deformation, and performance under specified loads. It uses shape optimization techniques to find the design with minimum stress that maintains structural performance. 3. The results of the ANSYS analysis on the CAD models are presented, including equivalent stresses, total deformation, and force calculations. The optimal solution is identified by comparing results to existing commercially available rotors.

1. CASE STUDY PRESENTATION
TOPIC : Stress Analysis Of disc brake rotor in static
condition .
Sr. no Name Roll No.
1 Prajwal badwaik. 108
2 Tushar Amale. 110
3 Pratik Gayakwad. 121
4 Ajay Dube . 122
Guide:
V.P.Kulkarni

2. TABLE OF CONTENTS
 Abstract
 Overview of case study
 Introduction
 Problem Definition
 Input parameter and calculation
 Result of analysis
 Conclusion
 Reference

3. 1) ABSTRACT
Disc brakes rotor design is varied for rotors of the same intended
use for many companies and some still use the same initial rotor
designs that were introduced over a decade ago. In this project
the investigation is done by modeling & analysis of different
shapes of slots of different vehicle’s disc brake rotor with same
outer diameter & inner mounting position of holes on wheel hub
as like Bajaj Pulsar 220cc. The modelling is done in CatiaV5 and
analysis is done in Ansys19.1. The stress level, deformation and
at specified load conditions is analyze and studied. The shape
optimization technique is used to find the optimum design
solutions. The outer diameter, inner diameter, mounting position
of holes on wheel hub is considered as the constraints for
design. The goal was to design a rotor with minimum stress level
and that maintains similar structural performance as rotors that
are currently commercially available. The optimal solution out of
modified rotor designs is finding out by comparing its results with
them and with the existing rotor. The optimise brake rotor.

4. KEYWORDS
2) INTRODUCTION
In design optimization problem there are objectives
and constraints that must be met with mechanical
design, size, weight, strength, and cost are a few of
the many constraints that may need to be taken into
consideration traditional methods of design rely on an
engineer or a team of engineers’ creativity,
experience, and intuition to come up with several
initial designs. These initial designs are compared
and analyzed using simplified models, from which the
best solution is chosen

5. 3)OVERVIEW OF THE CASE STUDY
• The motive of the case study to find out the stresses
which are acting on the different point of disc brake
rotor in static condition.
• By doing the considerations they designed the disc
brake rotor in designing software.
• Then they have founded the force acted by the
mounting bolt and by the brake pad on the surface of
rotor
• Then Aanalysis of forces is done in ansys in static
load condition
• Shown the result of analysis.

6. 4)PROBLEM DEFINITION
In the present work the aim is to find optimize disc
rotor solution of bajaj 220 cc disc brake rotor. The
structural shape optimization technique will be used
to optimize the disc brake rotor. The outer diameter &
inner mounting position of holes on wheel hub is
considered as the constraints for design. The
optimize disc FEM results will be compared with the
existing on the basis of stress, deformation and
weight.

7. 5)RESULT OF ANALYSIS
Cad model(CATIA) Meshing structure
Equivalent stresses Total deformation

8. 6)INPUT PARAMETERS AND CALCULATION

9. 7)CONCLUSION
 Hence, by using the given data and by doing the
considerations we are done the stress analysis.
 In static condition the forces which are applied on
the rotor are by the mounting bolt and brake pad.
 So the normal and tangential force acted by the
pad is founded theorotically .
 The result also verified using the ansys.

10. 8)REFERENCE
 International journal of innovative reserch in
science and engineering, vol.02,issue 08,august
2016.
 Automobile engineering by R K Rajput,2008.