This paper deals with design and analysis of disc brake rotor using composite material. Thecomposite material used is Aluminum Metallic Medium Composite it is a the combination of aluminum and silicon carbide length ways With a small percentage of other materials likemagnesium, aluminum oxide, graphite .These additional materials are added in accurate quantity to increase the chemical, mechanical and thermal properties ofmaterial. The manufacturing process is carried ready in organized location. Magnitude die casting process is used tomanufacture the disc brake using the composite material. In this paper the composite disc brakeismodeled in CATIA .The forces acting on the disc brake model are calculated using ADAMSsoftware.

1. http://www.iaeme.com/IJMET/index.asp 246 editor@iaeme.com
International Journal of Mechanical Engineering and Technology (IJMET)
Volume 8, Issue 2, February 2017, pp. 246–255 Article ID: IJMET_08_02_030
Available online at http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=2
ISSN Print: 0976-6340 and ISSN Online: 0976-6359
© IAEME Publication
MANUFACTURING AND FORCE DETERMINATION
OF COMPOSITE DISC BRAKE
R. Ramesh Kumar
Assistant Professor, Department of Mechanical Engineering,
Vel Tech Dr. RR & Dr.SR Technical University, Chennai, India
V. Thiruvengadam
Associate Professor, Department of Mechanical Engineering,
Vel Tech Dr. RR & Dr.SR Technical University, Chennai, India
J. Thamilarasan
Assistant Professor, Department of Mechanical Engineering,
Vel Tech Dr. RR & Dr.SR Technical University, Chennai, India
ABSTRACT
This paper deals with design and analysis of disc brake rotor using composite material. The
composite material used is Aluminum Metallic Medium Composite it is a the combination of
aluminum and silicon carbide length ways With a small percentage of other materials like
magnesium, aluminum oxide, graphite .These additional materials are added in accurate quantity
to increase the chemical, mechanical and thermal properties of material. The manufacturing
process is carried ready in organized location. Magnitude die casting process is used to
manufacture the disc brake using the composite material. In this paper the composite disc brake is
modeled in CATIA .The forces acting on the disc brake model are calculated using ADAMS
software.
Key words: Aluminum Metallic Medium Composite, Reinforcement, mixing casting, composite,
ansys, Disc brake.
Cite this Article: 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/issues.asp?JType=IJMET&VType=8&IType=2
1. INTRODUCTION
Aluminum mixtures are used in innovative presentations because of tall strong point, little density,
durability, machinability, accessibility and rate is precise beautiful compared to challenging materials. The
aluminum metallic matrix composite resources is the grouping of two or more elements in which one is
medium and further is filler materials (Reinforcements).Aluminum metal matrix may be coated, threads or
Particulates use composites. Usually, Grey cast iron is recycled to manufacture brake disc rotor, then again
Aluminum Metallic Medium Composite Designated considering critical compensations of the AMMC
(Al6061-3%SiC-9% red mud) concluded cast iron material. Disc brake used for braking or stopping the
vehicle or to keep a endless velocity or to common the automobile. This requirement dictates the right

2. R. Ramesh Kumar and V. Thiruvengadam and J. Thamilarasan
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choice of rigidity, chemical composition, tensile power and additional stuffs required for the planned use.
Several competing cars and airplanes usage with carbon fiber circles and carbon
Fiber plugs to decrease weight. In formulating metal medium composites by mixing casting way
several of the factors that basic considerable consideration are as follows:
 To attain even delivery of their reinforcement material
 To accomplish wet ability among the two leading substances
 To lessen porosity in the cast metal medium Composite
1.1. Brake Disc Rotor
The Disc Brake discs are usually mass- produced out of older cast iron. The SAE keeps a specification for
the production of older cast iron for various solicitations. For Regular car and light truck applications the
SAE requirement is J431 G3000 (superseded to G10). This requirement orders the correct assortment of
hardness, chemical configuration, tensile strength and further possessions required for the Intended use.
Racing cars and airplanes brakes with carbon fiber discs and carbon fiber pads are reduce mass. Attire
charges incline to be great and braking may be reduced until the brake is hot. It is examined that the
temperature supply, the thermal Bend and the thermal stress of locomotive discs have noiseless close
dealings with car safety; therefore, much research in this field has been done.
Figure 1 Construction
1.2. Aluminum Metallic Medium Composite (AMMC)
The period “composite” generally denotes to a material system which is composed of a distinct basic
distributed in unbroken phase, and which originates its Unique features from the possessions of elements,
from the geometry and architecture of Elements limits among elements. Composite materials are regularly
Confidential on the basis of the bodily or chemical nature of the medium phase e.g. polymer medium,
metal medium and ceramic composites. In AMCs one of the Elements is Aluminum/ Aluminum alloy
which Methods infecting network and is called as medium phase. The additional elements are fixed in this
Aluminum/ Aluminum alloy matrix and serve as Strengthening, which is usually non-metallic and
normally ceramic such as SiC and Al2O3. The Possessions of Aluminum Metallic Medium Composite can
be designer by variable the nature of elements and their volume portion.

3. Manufacturing and Force Determination of Composite Disc Brake
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Figure 2 Disc brake
The main advantages of Aluminum Metallic Medium Composite linked too unreinforced resources are
as follows,
 Better power
 Upgraded stiffness
 Condensed density (weight)
 Upgraded tall hotness properties
 Measured thermal enlargement coefficient
 Thermal/ temperature With standing 
 Improved and designer electrical presentation
 Controller of quantity (especially in reciprocating applications)
 Up graded damping competences. There has been attention in using







Figure 3 Animated brake
Aluminum created metal medium composites for brake discs and drum Resources in modern centuries.
While the abrasion and wear of Aluminum Metallic Medium Composite were extraordinary hurries and
loads the presentation would be critically better beyond that of iron discs, specified the right contest of pad
and disc quantifiable.

4. R. Ramesh Kumar and V. Thiruvengadam and J. Thamilarasan
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1.3. Reinforcement of Silicon Carbide
Silicon Carbide is the merely chemical composite of carbon and silicon. It was initially shaped by a
extraordinary infection electro-chemical response of sand and Carbon. Silicon carbide is an outstanding
rough and has been shaped and made into crushing wheels and further rough produces for terminated one
hundred centuries.
Nowadays the substantial has been established into high Quality mechanical grade ceramic with very
good automated properties. It is used in abrasives, refractoriness, terra -cotta and frequent high-
performance applications. The material can also be complete an electrical electrode and has submissions in
resistance warming, spark igniters and Microelectronic components. Silicon carbide is calm of tetrahedral
of carbon and silicon particles with tough unions in crystal matrix. This harvests a exact hard and Solid
material. The belongings of silicon carbide are defined as below. Automatically, silicon carbide has small
density, great strength, great hardness as well as extraordinary elastic modulus. Thermal possessions of
silicon carbide are also superb as it has low thermal extension, more thermal conductivity and admirable
thermal shock wave resistance. Also it has larger chemical dullness. As silicon carbide is additional in the
Aluminum Metallic Medium Composite as a strengthening, it also strengthens the whole properties of the
Aluminum Metallic Medium Composite. It expands the automatic properties of the Aluminum Metallic
Medium Composite; it raises the power and toughness of the composite. And also it increases the current
conductivity and warm air shock opposition of the material.
2. TREATING OF ALUMINUM METALLIC MEDIUM COMPOSITE
Crucial method for engineering of Aluminum Metallic Medium Composite at manufacturing measure can
be classified into two leading groups.
1) Fluid state developments:
a) Mixing casting
b) Penetration method
c) Sensitive Treating
d) Posy confession
2) Hard state developments:
a) PM handling
b) Circulation attachment
c) Corporal vapour statement.
2.1. Mixing Casting
Mixing casting is a procedure in which equally miscellaneous same well dust of flavors are diverse with a
molten medium metal by means of mechanical exciting. Mixing casting is the humblest and the maximum
cost real technique of fluid state creation. The fluid merged material is then cast by straight casting
techniques and may also be managed by conservative Metal creating technologies.
2.1.1. Stirrer
It is right significant limit in mixing casting method which is essential for vortex creation. The edge angle
and quantity of blades chooses the movement design of the fluid metal. The stirrer is engrossed till two
third deepness of molten metal. All these are compulsory for evens source of reinforcement in fluid metal,
unspoiled boundary connection and to elude gathering.

5. Manufacturing and Force Determination of Composite Disc Brake
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2.1.2. Pre- Heating of Supports
Casting method is very hard if strengthening elements are raining, also it outcomes in non-uniform
delivery and reduced machine-driven property. To circumvent this problematic, cavalries are pre-heated at
500°C for 40 minutes.
Table 1 Material Property
Sl no Parameters (grey cast
iron)
AMMC
(Al6061-
3%SiC-9%
red mud)
1 Youngs
modulus(GPa)
16.9e-3 73e-3
2 Poisson’s ratio 0.275 0.22
3 Density(g/mm3) 7.1e-3 85e-3
2.1.3. Pr e-Heating of Mold
Permeability is the main problematic in casting. In order to escape permeability heat up of mold is moral
resolution. Its supports eliminating airs slurry to drive the mold. It also improves the mechanical properties
of the cast AMC. Mold is excited to 500°C for one 60 minutes.
Figure 4 Model diagram
2.2. Patterns Proposal and Design
The Disc brake is modeled using CATIA software and the various forces found out using ADAMS
Software.

6. R. Ramesh Kumar and V. Thiruvengadam and J. Thamilarasan
http://www.iaeme.com/IJMET/index.asp 251 editor@iaeme.com
Figure 5 CATIA model
Figure 6 Assembly model
Figure 7 force calculate model
2.3. Mold Manufacture Method
In this stage we have arranged mould for casting sampling of several automatic trials like tensile
experiment, hardness experiment, torsion experiment, etc. In order to evade permeability warm up of mold
is moral result. It helps in eliminating the deceived airs from the slurry to go into the mold. It also increases
the mechanical effects of the cast AMC. Mold is excited to 500°C for one hour.

7. Manufacturing and Force Determination of Composite Disc Brake
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Figure 8 Ansys model
Figure 9 Ansys meshed model
2.4. Preparation of Reinforcement
Exact capacity of assistances is weighted and composed in crucible for moulding the arrangement of
Aluminum Metallic Medium Composite is given below:
Aluminum Oxide (Al2O3): 1.5%
Silicon Carbide (SiC): 3.5%
Graphite: 3.5%
Magnesium (Mg): 1.5%
Aluminum (Al): 90%
3. PLANNING OF ALUMINUM ESTABLISHED METAL MEDIUM COMPOSITE
(AMMC)
Aluminum alloy is prepared to eliminate dirt elements, evaluated and charged in the crucible for melting.
Nowadays strengthening powder and magnesium powder are considered on the balancing machine, they
arepre intense for 45 minutes at a high temperature 500. When medium was in the semisolid period state at
650°C, 1 % by weight of clean magnesium powder is recycled as saturating agent. Heater temperature is
then improved to800oC. At this heater temperature moving is happening and continual for five minutes.
Stirring rpm is regularly improved from 0 to 300 RPM with the help of speed organizer. Heated supports
are extra during five minutes of moving.

8. R. Ramesh Kumar and V. Thiruvengadam and J. Thamilarasan
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Figure 10 Equivalent Stress
Figure 11 Equivalent Stress (Grey cast iron)
Figure 12 Equivalent Strain (AMMC)

9. Manufacturing and Force Determination of Composite Disc Brake
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Material Equivalent
Stress
N/mm2
Equivalent
Strain
mm
Grey cast
iron
98.288 0.001246
AMMC 37.664 0.003415
Figure 13 Equivalent Stress (AMMC)
Figure 14 Total Deformation (Grey cast iron)
Supports are dispensed physically with the help of pointed hopper. Stirrer rpm is then regularly
depressed to the zero. Then melted composite slurry is transferred in mould minus giving time for
Sl
no
Material Stress
(MPa)
Displacement
(mm)
Contact
sliding
(mm)
Contact
pressure
(MPa)
1 cast iron 22.848 0.432e-3 0.525e-4 8.182
2 AMMC 8.286 0.120e-3 0.164e-4 7.694
3 Percentage
difference
14.562 0.000312 0.361E-04 0.488

10. R. Ramesh Kumar and V. Thiruvengadam and J. Thamilarasan
http://www.iaeme.com/IJMET/index.asp 255 editor@iaeme.com
strengthening to relax down at container bottom. Mould is heated at 500°C heat for one hour before hand
bucketing the molten slurry in the mould. This is essential to continue slurry in molten situation all over
the pouring. Mould is then permissible to cool and after freshening runner, risers are unconcerned from
disc. Final concluding is done using lathe machine to attain dimensional precision.
4. CONCLUSION
Following decision is drawn from directly above paper:
1. Gravity mixing casting is maximum economical method used for casting of AMMC.
2. Pre warming of mould decreases absorbency and improves mechanical things.
3. Pre heating system of strengthening outcomes inconstant delivery and improved mechanical properties.
4. Adding of Magnesium is significant to growth wet ability.
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