This document summarizes a structural analysis of a brake disc conducted by students. They modeled a disc brake in ANSYS, applied appropriate loads and boundary conditions, and analyzed the results. Von Mises stresses were highest at the inner area where the shaft connects. Deflections and stresses obtained indicate the cast iron disc can withstand the applied pressure. The analysis can be improved by modifying the material or design, or adding ventilated areas to withstand thermal variations.

1. STRUCTURAL ANALYSIS OF
A BRAKE DISC
By
A. Pravalika (12N31A2101)
Vedprakash Arya (12N31A2105)
B. Ravi Kumar(12N31A2106)
B. Prudhvi Raj (12N31A2110)
Under the guidance of
Mr. SHAILESH BABU
Asst. Professor
Department of Aeronautical Engineering, MRCET.

2. ABSTRACT
The present investigation is aimed to study the given disc
brake rotor of its stability and rigidity, for this structural analysis is
carried out on a given disc brake rotor. In this project the specified
dimensions of the disc brake are taken for modeling in the software
ANSYS. Static analysis was carried out on the disc brake
considering the significant support structures with respective of
disc. In analysis part, the finite element of portion of the disc is
created, appropriate boundary conditions are applied, material
properties are given and loads are applied as per its design. The
resultant deformation and stresses obtained are reported and
discussed.

3. INTRODUCTION
❑ The disc brake is a device used for slowing or stopping the
rotation of the wheel.
❑ A brake is usually made of cast iron or ceramic composites
include Carbon, Aluminium, Kevlar and Silica.

4. BRAKING REQUIRMENTS
❑ The brakes must be strong enough to stop the vehicle with in
a minimum distance.
❑ The brakes must have well anti fade characteristics i.e. their
effectiveness should not decrease with constant prolonged
application.

5. “The principle used is the applied force (pressure) acts on
the brake pads, which comes into contact with the moving disc.
At this point of time due to friction the relative motion is
constrained.”
PRINCIPLE

6. WORKING
When the brakes are applied, hydraulically actuated
pistons move the friction pads in to contact with the disc,
applying equal and opposite forces.

7. DISC BRAKE COMPONENTS

8. APPLICATIONS
❑ MOTORCYCLES
❑ Bicycles
❑ Cars
❑ OTHER VEHICLES

9. ADVANTAGES
❑ Good braking at both low and high speeds
❑ Light weight
❑ Anti-skid protection
❑ Simple installation

10. DISADVANTAGES
❑ It is expensive compare to drum brake.
❑ If any air remains in disk brake system, it can cause accident
as the brake will not work effectively.
❑ Disk brake assembly has more moving parts and much
complex than drum brake.

11. PROCEDURE
Disc Brake has been modelled with the help of
ANSYS v16.0 software. The Orthographic and Solid
Model of Disc Brake is shown in the figures. The following
is the list of steps that are used to create the required
model.

12. CONSIDERATIONS
Following Considerations are done for our
project.
❑ Young’s modulus=2x105N/m2
❑ Poissions ratio=0.3
❑ Pressure=500N/m2
❑ Density=7800Kg/m3

13. Model generation
❑ STEP 1: From the Main menu select Preferences. Select
structural and press OK.
❑ STEP 2: From the main menu select Pre-processor.
Element type → Add / edit/Delete → Add →SOLID-10 node
187 → Apply → Close.
Material properties → material models → Structural →
Linear → Elastic → Isotropic–

14. Young’s Modulus = 2x105N/m2.
Poissions ratio = 0.3;
Density =7800Kg/m3.
❑ STEP 3: From the main menu select Pre-
processor.
Modelling → Create→ Key points → In Active
CS→ enter following points→ Apply→ for last
key point value press Ok.
S. No. Key point
1 (0,0,0)
2 (30,0,0)
3 (30,-12,0)
4 (70,0,0)
5 (58,-12,0)
6 (58,-60,0)
7 (70,-36,0)
8 (131,-36,0)
9 (131,-60,0)
10 (0,-10,0)
Fig. Table for keypoints.

15. ❑ STEP 4: From the main menu select Pre-processor.
Modelling: Create → lines → Straight lines → Select two
points through which a line has to be created similarly
create lines through the points
2-4, 4-7, 7-8, 8-9, 6-5, 5-3, 3-2.
❑ STEP 5: From the main menu select Pre-processor.

16. Fig. Initial modelling
Modelling: Create → Areas → Arbitrary → by lines → select all
lines → apply → OK

17. ❑ STEP 6: From the main menu select Pre-processor.
Modelling: Operate → Extrude →About axis → Arc length
in degrees=360;
Fig. Disc Brake model

18. MESHING OF THE MODEL
Meshing is done on the Disc Brake for easy solving and
accurate results in ANSYS.
❑ Meshing the Geometry. From the
main menu select Pre-processor.
Meshing → mesh tool→ element
attributes-global→mesh-
volumes→ mesh. Select all
volumes→ Click OK.
Fig. Meshed model

19. APPLYING BOUNDARY CONDITIONS
❑ STEP 1: Defining loads at the Areas.
Solution → Define Loads → Apply→Structural
→Displacement→ On Areas Left circle area –ALL DOF
arrested.
❑ STEP 2: Solution → Define
loads → Apply →Structural
→Pressure→On Areas
Fig. Arresting disc

20. Select the area where shaft is to be placed – Apply
pressure = 500 N/m2.
❑ Solution: Solution → Solve → Current LS → OK →
Solution is done → close.
Fig. Applying loads at inner area.

21. RESULTS
Fig. Von Mises stresses. Fig. Nodal solution of
a disc brake in X direction

22. Fig.Nodal solution of
a disc brake in Y direction
Fig.Nodal solution of
a disc brake in Z direction

23. OBTAINED VALUES
S. N. VALUES NODAL SOLUTION ABOUT AXIS PRINCIPLE STRESSES
X Y Z 1st 2nd 3rd
1 DMX (m) .1667 .101E-05 .101E-05 .101E-05 .101E-05 .101E-05
2 SMN (N/m2) -510.01 -1097.03 -3048.67 -219.652 -337.84 -3057.05
3 SMX (N/m2) 781016 885.312 4722.35 4797.16 758.736 38.2384
S. N. VALUES VOLUME CONTOURS SHEAR STRESSES
XY XZ YZ
1 DMX (m) 0.101E-05 .101E-05 .101E-05 .101E-05
2 SMN (N/m2) 4.90814 -2236.598 -3836.48 -258.463
3 SMX (N/m2) 2209.91 274.497 3703.08 230.23
Table: 1
Table: 2

24. CONCLUSION
❑ The inner area of the disc where shaft is to be placed will be
affected more than any other part of the disc.
❑ On analysing the defections and stresses obtained as a result of
given pressure.
❑ The Cast iron disc which is considered here can withstand for
this pressure.
❑ Thus the further experiment can be conducted with addition of
pressure and can be analysed.

25. FUTURE SCOPE
❑ Since the brake disk design is safe based on the strength and
rigidity criteria. But the stresses observed in the results are not
adequate with the practical scenarios.
❑ To improve the performance of the disc brake, material and
design, modifications can be made on structural design. Also, a
model with ventilated area which can withstand both structural
and thermal variations, is suggested.

26. …THANK YOU…