Disc Brake Rotor Research Articles

Computational Study on Structural and Thermal Behavior of Aircraft Disk Brake Rotor for Different Materials

Brakes are one of the most significant safety systems in an aircraft. The rotor will be exposed to large stresses which result in surface cracking, overheating of brake fluid, seals and other components during the braking process. Thus, one of the main tasks for the design of braking system is to reduce the stress, deformation and surface temperature of the brake rotor. This can be achieved by choosing the right material which will undergo the least thermal stresses. In this research a detailed study of structural and thermal analysis is carried out for disc brake rotor of DHC-6 Twin Otter with different materials. The objective of this research is to provide an efficient material for disc brake rotor which can dissipate heat generated during braking at faster rate and also being structurally safe. The materials chosen for the study are Mild Steel, Grey cast iron, Stainless steel, Cabon-carbon composite and Aluminum silicon carbide MMC. From the structural and thermal analysis it was found that the aluminum silicon carbide MMC disc brake rotor exhibits the superior performance against other materials with a mass of 2.37 Kg, deformation of 0.043617 mm, maximum stress of 167.91 MPa, maximum temperature of 250.85 oC and heat flux of 5.2043 W/mm2. The mass, stress, deformation and temperature developed in the aluminum silicon carbide MMC rotor is less than the original stainless steel rotor by 61.3%, 3.66%, 6.9% and 35.6% respectively. Similarly, the aluminum silicon carbide MMC rotor provides better heat dissipation as compared to original rotor due to an increment in heat flux by 15.26%.

Design and Analysis of an Automobile Disc Brake Rotor by Using Hybrid Aluminium Metal Matrix Composite for High Reliability

Due to their superior capabilities for manufacturing lightweight automotive components, aluminium metal matrix composites have gained a lot of attention in the last few years. Aluminium metal matrix composites are an exceptional class of metal matrix composites that can solve all the major problems related to the automobile industry. Aluminium matrix composites in the disc braking system have already been employed and studied by many scientists. However, the developed materials are not yet always sufficiently accurate and reliable. In this article, a new enhanced metal matrix composite material is used and studied to improve the efficiency of an ordinary car’s braking system. To improve the accuracy of the designated braking system, an innovative hybrid aluminium matrix composite (Al6061/SiC/Gr)-based brake rotor has been developed, and its effectiveness has been determined by finite element analysis. From the simulation, the product performance confirmed that the hybrid aluminium matrix composite (Al6061/SiC/Gr)-based brake rotor has the potential to replace the standard cast iron brake disc. The new enhanced hybrid composite material used in this study can be used for the efficient design of various braking parts.

Designing Disk Brake Rotors: A Practical Approach

Abstract: Disc brake rotors play a critical role in the performance and safety of automotive braking systems. This paper presents a design and optimization methodology for disc brake rotors aimed at improving their durability, thermal performance, and weight reduction. The proposed approach combines analytical modelling, numerical simulations, and optimization techniques to achieve an optimal rotor design. The results demonstrate the effectiveness of the proposed methodology in enhancing the performance of disc brake rotors.

Modeling the Mechanical Properties and Stress Mapping of Aluminium Based Metal Matrix Composite Used in Brake Disc Rotor

Modeling the Mechanical Properties and Stress Mapping of Aluminium Based Metal Matrix Composite Used in Brake Disc Rotor

Coupled thermal and structural analysis of disc brake rotor with varying angle of rotation of ventilation holes

The automobile’s speed and torque requirements are growing all the time these days. As we all know, not only are speed and torque are a necessity of automotive manufacturers, but also braking without sliding and vehicle comfort is also a fundamental element. The major goal of this project is to study the impact of inclined holes on the disc brake rotor similar to that of Suzuki GSXR 1100 which will decrease overall deformation and maximize heat dissipation. AUTODESK FUSION 360 is used to create various forms of vented holes in a brake disc rotor. The inner and outer boundaries are retained, with changes occurring only in the intermediate patterns/regions between them, giving the models similar structural boundary limitations. ANSYS, a finite element software for calculating the temperature distribution, fluctuation of stresses and deformation throughout the disc brake profile, is utilized for the static structural analysis and steady-state thermal analysis of the brake disc rotor. To improve the quality of the results a coupled static structural and thermal analysis simulation was performed which showed a linear decline of temperature and total deformation with an increase in the angle of the holes. Thus, the effective lifetime of the disc brake rotor will be increased. Based upon the values of von-misses stresses, deformation, temperature, total heat flow obtained via ANSYS simulation, the best design changes in the brake disc rotor are proposed.

Thermal Analysis of Disc Brake System

Abstract: Brakes are one of the most significant safety systems in an automobile. In the braking process, the rotor will be exposed to large stresses which result in surface cracking, overheating of brake fluid, seals and other components. Therefore one of the main tasks of the braking system is to reduce the surface temperature of the brake rotor. This can be achieved by choosing the right material which will undergo the least thermal stresses. In this project, thermal analysis for vented disc brake rotor of Mahindra Bolero’s done, for providing an efficient material for disc brake rotor and brake pads which can dissipate heat generated during braking at faster rate and also being structurally safe. Keywords: Braking system, Disc Brake Rotor, Thermal, Structural Analysis, CATIA V5, ANSYS WORKBENCH

Transient Thermal Analysis of Disk Brake System under Varying Velocities and Pad Material Properties

Abstract: The Enormous progressions in the field of automobiles have led their car engines to have enriched brake power in vehicles. The braking system’s efficiency should be at par with the engine to decelerate the car from a given speed within a less braking distance. The disc rotor and brake pads design and material while counting other impacting factors contribute to braking efficiency. The disc rotor will be exposed to large stresses which result in surface cracking, overheating of brake fluid, seals and other components. Many factors are affecting it as coefficient of friction between brake pad and disk rotor surface, thermal conductivity of pad material. Hence to reduce thermal stresses we can choose right pad material. In this project, thermal analysis for vented disc brake rotor of Mahindra Bolero’s done, for providing an efficient material for disc brake rotor and brake pads with 0 to 12 % of steel powder as filler materials are used which can dissipate heat generated during braking at faster rate and also being structurally safe Keywords: Braking system, Disc Brake Rotor, Thermal, Structural Analysis, CATIA V5, ANSYS WORKBENCH, Pad Material properties

Laser Cladding Treatment for Refurbishing Disc Brake Rotors: Environmental and Tribological Analysis

In this study, grey cast iron disc brake rotors are refurbished by adding a surface layer through laser cladding. Current methods to deal with replaced rotors mainly include remelting, with a minority fraction disposed in landfill. Both approaches result in a huge waste of resources and an increase in CO2 footprint. From a sustainable point of view, this study aims to evaluate the feasibility of refurbishing brake rotors by a combined environmental and tribological performance approach. A streamlined life cycle assessment is conducted to compare the environmental impacts between producing virgin grey cast iron brake rotors and refurbishing replaced brake rotors by laser cladding. It turns out that the energy consumption and CO2 footprint of the laser cladding refurbished brake rotors are 80% and 90% less than the virgin brake rotors. The results show that the refurbished brake rotor yields higher friction compared to the original cast iron utilizing the same pad material. The wear and particle emissions of the disc brake contact are in this study higher for the laser-cladded one compared to the original cast iron one.

Enhancement of mechanical properties and tribological properties of aluminum using Iron(Fe) and Nickel(Ni) additives

Inmodern times it is seen that the use of aluminum alloys has increased greatly in automobile, aerospace, marine, and various other fields. This is due to the fact that aluminum alloys have superior advantages when it comes to corrosion resistance, strength to weight ratio characteristics, and high machinability when it is compared with steel. In this paper a study on the mechanical, tribological properties and microstructure of aluminum alloy with variations in Nickel (Ni) and Iron (Fe). Previous studies that have been conducted in this field have dealt with aluminum additives of different compositions with the study of only mechanical properties or microstructure. Our project deals with the study in the changes of properties and microstructure analysis of Iron(Fe) and Nickel(Ni), aluminum-based alloy added to which the tribological studies and the correlation is studied with the variations in the metal concentration, Thus the study and development of these alloys are important as it paves the way for the new generation of mechanical components with superior properties. Also, our paper deals with the fabrication of a brake disc rotor with the most suitable alloy among the three. The tensile strength, hardness, and surface characteristics of all the profiles were studied in detail and presented. The 7% of Iron powder in the profile has the highest tensile strength.

Optimization of ventilated brake disc rotor geometry for enhanced structural characteristics

This paper focuses on analyzing the effect of geometrical parameters on structural performance of the ventilated brake disc. Multi-objective optimization through response surface methodology was deployed for improving the structural performance of ventilated brake discs. Simulation runs were designed based on central composite design technique. The second order regression models correlating the geometry parameters with maximum deformation and equivalent stress were developed. ANOVA was performed to test the significance of disc geometry parameters. The deformation and equivalent stress were influenced by flange outer peripheral radius. While the spigot radius had a significant effect on the deformation but not on equivalent stress. Also, the mounting surface radius influenced the equivalent stress developed on the ventilated brake disc rotor. The multi-objective optimization of geometrical characteristics for minimum deformation (4.2332 µm) and minimum equivalent stress (4.00989 MPa) yielded significant reduction in total deformation and equivalent stress i.e., 10.28 % and 9.12 % respectively at optimal levels of geometrical parameters.

Experimental Investigation on the Frictional Wear Behaviour of TiAlN Coated Brake Pads

The brake pad is one of the imperative portions of the braking system of any automobile; which is mounted on a brake-disc rotor on each wheel; the brake pads were made by different types of materials. In recent research focuses on using Titanium (Ti) alloy-based brake pads for sophisticated cars (lightweight automobiles) and sports cars because of its high fracture toughness at low density. The most commonly preferred grade of Ti alloy is Grade 2 with 99.5% pure, but in the recent research, it was found that the Ti alloy grade 5 has good thermal stability; so, it can withstand a high tribo-thermal zone like the braking system. This study aims to investigate the frictional wear behaviour of the Ti alloy grade 5 and its performance and it is improved furtherly coating with Titanium Aluminium Nitride (TiAlN). The TiAlN is coated over the Ti alloy using Cathodic Arc Deposition (CAD) method; its surface properties such as surface hardness, surface morphology, surface roughness, and coating thickness are characterized. The wear test is conducted to the TiAlN coated Ti discs as per ASTM G99 (American Society for Testing and Materials) in against OHNS balls (Oil Hardened Nickel Steel). The Coefficient of Friction (COF) of the TiAlN coated Ti alloy has been reduced twice the time when compared with the uncoated Ti alloy. The surface morphology of the worn surfaces studied after the wear test to study the causes of the phenomenon. It reveals that the enhanced surface properties and better resistance to micro thermal effects are reasons for the improved wear resistance of the TiAlN coated Ti alloy.

Impact of Design Factors of Disc Brake Rotor on Braking Performance

Impact of Design Factors of Disc Brake Rotor on Braking Performance

Topology Optimization of Disc Brake Rotor

The main purpose of this study is to analyze the thermo-mechanical behavior of the brake disc during the braking phase. Brakes must undergo through continuous use, so many issues surround their heating characteristics when it comes to their development, including contact region properties, material choice, and development of hot spots, associated physical geometry, and deformations. The coupled thermal-structural analysis is used to determine the deformation and the Von Misses stress established in the disc to enhance performance and life of the rotor disc. A comparison between analytical calculations and results obtained from Finite Element Analysis (ANSYS) is done and the values obtained from the analysis are in the range of allowable values. The experiment has been performed with different disc-geometries. Based on the experiment results we have performed ANSYS simulation for the disc-brake. Hence best suitable optimum design is suggested based on the performance, strength and rigidity criteria.

Comparative Analysis of Disc Brake Rotor using CFD

Comparative Analysis of Disc Brake Rotor using CFD

Study of Difference in Friction Behavior of Brake Disc Rotor with Various Surface Textures during Running-In by Using Simple Model

Study of Difference in Friction Behavior of Brake Disc Rotor with Various Surface Textures during Running-In by Using Simple Model

Tribological properties of aluminium-clay composites for brake disc rotor applications

In this paper, the mechanical and tribological behaviours of various compositions of aluminium 6063 alloy – clay (Al-clay) composites for brake pad applications were studied. The Al-clay composites with 5–30wt% of clay particles of grain size of 60 BSS (250 microns) were developed through stir casting route. The wear characteristics of Al-clay in dry sliding conditions were subjected to a series of Denison T62HS pin-on-disc wear tests. The action of two different loads (4 and 10N), three sliding speeds of 200, 500 and 1000rpm were investigated. The results of the mechanical and wear tests as well as the metallographic investigation of optical, scanning electron microscopy and energy dispersive X-ray microscopy revealed an improvement in the tensile strength, hardness and wear resistance in the composites with 10–25wt% clays. The best values were obtained at 15wt%. Wear rate was highly influenced by applied load and sliding speed. The developed composites with 15–25wt% clay addition were similar to conventional semi metallic brake pad in terms of wear and friction properties.

이종 재질 디스크 브레이크 로터 마찰면 가공 형태에 따른 성능 변화 연구

이종 재질 디스크 브레이크 로터 마찰면 가공 형태에 따른 성능 변화 연구

Improvement in Wear and Thermal Resistance of Disc Brake Rotors using TiAlN Coating

Improvement in Wear and Thermal Resistance of Disc Brake Rotors using TiAlN Coating

Steady State Thermal Analysis of a Disc Brake Rotor with Composite Material

Steady State Thermal Analysis of a Disc Brake Rotor with Composite Material

Vibrational Analysis of Disc Brake Rotor of a Two Wheeler to find the defect using FEA

Vibrational Analysis of Disc Brake Rotor of a Two Wheeler to find the defect using FEA