Project consist of two types of analysis thermal , structural & VBA Programming. Thermal analysis is done to check the thermal resistance of model Honda Unicorn 160. Structural analysis is done to find the strength of the model. VBA programming is used to automate drafting task.

1. A PROJECT ON
THERMAL & STRUCTURAL ANALYSIS
ON DISC BRAKE ROTOR WITH DRAFTING USING CATIA - VBA
Under the guidance of
 Asst.Prof. Dhole P.V.
Presented by
 Bachchewar Rohit
 Gadkari Ambika
 Suryawanshi Nitin
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2. Contents
 INTRODUCTION
 LITERATURE REVIEW
 ABSTRACT
 Problem Statement
 Overview of disc brake
 CAD Designs
 Thermal Analysis
 Structural Analysis
 VBA Programming
 Conclusion
 Future Scope
 References
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3. INTRODUCTION
 In today’s growing automotive market the competition for better
performance vehicle is growing enormously.
 The disc brake is a device for slowing or stopping the rotation of a wheel.
 Brake convert K.E. to Mechanical energy(Heat).
 Project consist of two types of analysis thermal , structural & VBA
Programming.
 Thermal analysis is done to check the thermal resistance of model Honda
Unicorn 160.
 Structural analysis is done to find the strength of the model.
 VBA programming is used to automate drafting task.
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4. LITERATURE REVIEW
Title Author Review
1. Computer Aided Design &
Analysis of disc brake rotors for
passenger cars
Dr. R. Udaya kumar
& Ramesh
Ponnusamy(2013
IEEE)
The purpose of this
research is to analyze
different types of disc
brake rotors.
2. Design And Analysis Of
Brake Rotor With Parameter
Optimization.
Harshal Nikam,
Prem Mishra &
Sayali Bharambe
(2104 IJAuERD)
Brake fading and thermo-
elastic deformation of
brake rotor is frequently
found problem in custom
made rotors.
3.The Disc Brake Design &
Performance Analysis
Sun Li & Liu Youg-
chen (2011 IEEE)
the performance and
parameters matches of
disc brakes directly
impacts on the vehicle
safety.
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5. ABSTRACT
 The disc brake is a device used for slowing or stopping the rotation of
the vehicle. Number of times using the brake for vehicle leads to heat
generation during braking event, such that disc brake undergoes
breakage due to high Temperature. Disc brake model is done by
CATIA/CREO and analysis is done by using ANSYS workbench. The
main purpose of this project is to study the Thermal analysis of the
Materials for the GRAY CAST IRON. A comparison between the four
models for the Thermal values and material properties obtained from
the Thermal analysis low thermal gradient model is preferred.
 Also in this project we added a VBA Programming for Disc Modeling.
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6. Problem Statement
 A problem in disc brake occurs because of uneven stress &
heat dissipation during braking of two wheeler as follows-
 Cracking , rusting, poor stopping ,noise, vibration , pulling,
dragging, pulsation etc.
 The material of brake is subjected to high compressive stresses
hence it affect the overall area of disc rotor.
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7. Overview of disc brake
 A brake is a device through which frictional resistance is applied to
moving machine member, to stop the motion of machine.
 The energy absorbed by brake is dissipated in the form of heat.
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8. Original Design of Unicorn 160
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13. Thermal Analysis
 Objective :-
 Evaluating the performance of disc brake of bike under
various braking condition.
 To study the heat & temp distribution and results are
compared for better performance.
 To find out total heat flux capacity among the 4 CAD
models.
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14.  Inputs
 Material of Disc = Gray Cast Iron
 Thermal Conductivity = 53.3 w/mk
 Density (ρ) = 7060 kg/m3
 Specific heat = 490 J/kg k
 Film coefficient = 280 w/m2k
 Mass of vehicle (m) = 135kg
 Brake pad area = 2800 mm2
 Initial velocity (u) = 27.77 m/s (100kmph)
 Vehicle speed at the end of braking
application (v) = 0 m/s
 Brake rotor diameter = 240 mm
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15. Original/Existing Disc
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17. Structural Analysis
 It is the determination of effects of lodes on physical
structure & their components.
 Problem of analysis of structural that it subjected to
dynamic loads are considered in dynamics of structure
 Objective :-
 To ensure the reliability & durability of structures, given
an economically sound expenditure of materials.
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18. Structural Analysis
 Inputs:-
 Tangential Force between pad & rotor on
inner surface
Ft1 = 1120 N
 In this case equal to Ft1 because same
normal force & same material
Ft2 = 1120 N
F = 1120 + 1120 = 2240 N
 Moment = F×d
= force applied × Distance from fix axis
= 2240 × 0.120
M = 268.8 Nm
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22. VBA Programming
 Visual Basic Programming Language (VBA)
 To reduce time span of design modeling.
 To understand VBA firstly we know the what is mean
by macro & VB script…?
 A macros is a series of functions , written in a scripting
language , that you group in a single command to
perform the requested task automatically.
 VB script is a subset of the visual basic Programming
Language .
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23. Flow Chart for manual modeling
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27. Conclusion
 From the study of various designs patterns for gray cast
iron material it is observed that the disc having max
surface area will dissipate more heat & final temp after
braking.
 It improves overall brake performance of disc brake.
 Initial designs are compared & analyzed using simplified
models from which best solution is chosen.
 Decreasing amount of physical testing for new design.
 The temp distribution throughout the disc rotor is uniform
 Due to VBA time for modeling of disc is reduced.
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28. Future Scope
 Thermal analysis of the disc brake with different
materials.
 Structural analysis of disc brake with different
materials.
 Automate the design procedure & reduce time of
modeling.
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29. References
 Dr. R. Udaya kumar 2013 IEEE paper on Computer Aided Design & Analysis of disc
brake rotors for passenger cars.
 2. Harshal Nikam, Prem Mishra & Sayali Bharambe International Journal of
Automobile Engineering Research & Development (IJAuERD) ISSN(9):2277-
4785;ISSN(E);2278-9413 Vol-4,Issue 4,Aug 2014,21-30 paper on Design And Analysis
Of Brake Rotor With Parameter Optimization.
 3. Sun Li & Liu Youg-chen from chian, 2011 IEEE the performance and parameters
matches of disc brakes directly impacts on the vehicle safety.
 4. Brakes and Dynamometer”-Theory of Machine by R.S. Khurmi & J.K. Gupta-732
 5. Heat Transfer- by Rajput
 6. Disc Brake” - http://en.wikipedia.org/wiki/Disc_brake
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30. Thank you…..!!!
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