Design and Analysis of Brake Component

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 07 | July 2022 www.irjet.net p-ISSN: 2395-0072
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Design and Analysis of Brake Component
Akshat Ruhela1, Aayush Srivastava2
1,2 Student, Department of Mechanical Engineering, ABES Engineering College, Uttar Pradesh, India
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Abstract - The performance and success of any vehicle dependontheabilityofitscomponentstofunction properlyunderany
conditions such as wet track, dry track, and off-road terrains. The performance of the vehicle can further be improved by
making the components more robust along with the proper reduction in their weight. The safe operation of any vehicle
requires constant adjustments of its speed under changing traffic conditions and the brake discisanimportantcomponentfor
the deceleration and maintaining the speed of a vehicle under control which includes stopping. This researchpaperstudiesan
optimized design of the brake disc which aims at reducing weight and maintaining the strength along with reducing the
deformation at higher temperatures as compared to the OEM available in the market. The brake disc is being modelled in
SOLIDWORKS and analysed via FEA in ANSYS for static and thermal loads
1. INTRODUCTION
Brake is a component used to deaccelerate a vehicle. Main components of brake are Brake pedal, master cylinder, hydraulic
pressure sensors, the brake hoses, hydraulic control unit (ECU), caliper anddisk. Brakepedal designingplaysa veryimportant
factor in the force analysis of master cylinder as there is always a space constraint in designing an ATV resulting, that driver
will not able to apply force on pedal such that on regular vehicles. During brake pedal design space constraint and resting
position of a driver should be comfortable for applying force sufficient to drive master cylinder to its full stroke.
2. LITERATURE REVIEW
• [1] K. Sowjanya, S. Suresh, “Structural Analysis of Disc Brake Rotor”, International Journal of Computer Trends and
Technology (IJCTT), Vol.4 Issue 7–July 2013
• [2]Neeraj Singh, R.S. Bharj, Kamal Kumar,“OptimumDesignandExperimental AnalysisofBrakeSystemforBAJAATV”,
International Journal of Research in Management, Science & Technology (E-ISSN: 2321-3264) Vol.5,No.3,December
17”.
• [3]Vivek Singh Negi, Nayan Deshmukh, Amit Deshpande, “DesignandAnalysisofBrakesystem”,International Journal
of Advance Engineering and Research Development Vol-4(11), November -2017”.
• [4]Kush Soni, Gaurang Vara, Ishit Sheth, Harshil Patel, “Design and Analysis of Braking System for ISIE ESVC”,
International Journal of Applied Engineering Research ISSN 0973-4562 Vol-13, Number 10 (2018) pp. 8572-8576”.
• [5] K K Dhande , N I Jamadar and Sandeep Ghatge July 2014 “DESIGN AND ANALYSIS OF COMPOSITE BRAKEPEDAL:
AN ERGONOMIC APPROACH”, International Journal of Mechanical Engineering and Robotics Research (IJMERR),
Volume 3(3), pp. 474–482.
• [6] Nand Mangukia and Nandish Mangukia 2018 “Design and Fabrication of Brake Pedal for All Terrain Vehicle
“,INTERNATIONAL JOURNAL OF ENGINEERINGDEVELOPMENTANDRESEARCH (IJEDR),Volume6(2),pp.562 – 568.
• [7] Miss. ASHWINI N.GAWANDE, Prof.G.E.KONDHALKAR, and Prof. ASHISH R.PAWAR , May -2017 “STATIC
STRUCTURAL ANALYSIS AND OPTIMIZATION OF BRAKE PEDAL”, International Research Journal ofEngineeringand
Technology (IRJET), Volume: 04(5), pp. 3222-3227.
3. METHODOLOGY
This study is completed in 2 parts. First part covers the modelling and analysis of stress generated in the component, second
part covers the study of stresses and optimisation of the brake pedal through the concept of biomimicry. CAD model of the
brake pedal is developed in Solidworks and the FEA analysis has been carried out in ANSYS Workbench 2019 R1.

Approach of this study has been show in Fig-1
4. DESIGN: CALCULATIONS
××Calculation for Deacceleration××
V2 – U2= 2as
0 = 16.672 + 2a×8
-16a = 277.556
a = - 17.34 m/s2
××Calculation for Stopping time××
V = U+ at
0 = 16.67 –17.34 t
Initial calculations and design
considerations.
CAD Modelling (Creo parametric 5.0)
FEA Analysis (ANSYS Workbench 2019 R1)
Study of stresses generated
Optimisation of CAD Model
Again FEA Analysis (ANSYS Workbench 2019 R1)
Design
Evaluation
Design
Evaluation
Final result and finish
YES
NO
Yes

t=
t = 0.96 sec
Calculation for weight distribution and required braking force
RF = W × (a + coefficient of friction *h) ×cos ( )
= 2452.5 ×
RF = 1858.13N
MASS ON FRONT AXLE DURING DYNAMIC CONDITION
= = 189.41 kg
Mass transfer on front axle during braking = 189.41 kg
Front braking force required for front axle =
189.41 × 17.34 = 3284.36N
Force required for each wheel =
= 1642.18 N
Torque required for each wheel = F Front wheel × Wheel radius
= 1642.18 241.3
= 396.25 N m
T Front wheel = TFront rotor
T Front wheel = F rotor rotor radius
FRotor =
=
Frotor = 3635.32 N
5. MATERIAL SELECTION
The brake pedals are made from different materials such cast iron, aluminium, and mild steel. A detailedstudywas carried out
to select the most suitable material depending on the factors such as availability of material, Yield strength, weight, cost,
weldability. AL-7075 T6 was selected over Grey based on availability, cost, Yield strength and fatigue strength.

6. DESIGN: CAD MODELLING
The initial CAD model of the brake pedal has been created in Solidworks 2019. It consists of mounting points for itself and 2
master cylinders. The design processes were started with defining and evaluating all the design constraints.
Fig 1: - Model Of Disc Brake
7. MESHING
The CAD model is imported into ANSYS Workbench 2019 R1. The automatic mesh with size 1mm is used for this study.
Nodes 134283
Elements 73230
Fig -2: Mesh Model

8. ANALYSIS
Figure :- Equivalent Stress
Figure :- Factor of Safety
Figure:- Steady State Thermal

9. DESIGN: INITIAL CAD MODELLING: Brake Pedal
The initial CAD model of the brake pedal has been created in PTC Creo Parametric 5.0. It consists of mounting points for itself
and 2 master cylinders. The design processes were started with defining and evaluatingall thedesignconstraints.Themodeof
manufacturing for this brake pedal is welding of laser cut parts. The geometry also includes fillets of 4mm around the footrest
and pivot region to represent weld bead. Initial CAD model of the brake pedal is
Boundary conditions:
 A of 2000N is applied normally by driver in –x axis on the foot rest.
 The pivot point is fixed.
 Force of 45N is applied in –x axis to simulate the force presented by master cylinders.
Nodes 134283
Elements 73230

Study of generated stresses:
The second part of this research includes the optimisation of brake pedal to minimise the weight of the component and to
remove extra material. The inspiration for optimisation was drawn from a honeycomb structure. A honeycomb structure
provides rigidity and efficient stress distribution along with minimal weight.
The von-Mises stresses and safety factor obtained from the analysis are used to map the region where the optimisation study
can be carried out in order to remove extra material. The region where the optimisation study is needed is shown in Fig*. The
Red region defines the design space where the optimisation study is carried out; the stresses in this region are low which

contributes to high safety factor which in turn means that there is excess material available in this region. The yellow region
encloses the space where high stresses are being generated thus no optimisation study is required in this region.
DESIGN: OPTIMISATION CAD MODELLING
The optimised CAD model of the brake pedal has been created in PTC Creo Parametric 5.0. It consists of mounting points for
itself and 2 master cylinders. The Design space has been optimised with a hexagonal lattice structure for weight reduction.
Optimised CAD model of the brake pedal is shown in Fig*
ANALYSIS:
The Mesh and boundary conditions are kept same for the second analysis.

Results:
Maximum Equivalent von-Mises Stress = 363 Mpa Minimum Safety Factor = 1.02
Maximum displacement = 2.6mm
Mass – 74 grams Mass – 122 grams

10. CONCLUSION
1. Upon comparison it was observed that the design 2 of Generative design Model has the highest factor of safety for similar
working conditions i.e. "2.6257" and weight of the brake pedal was reduced from "256 grams" to "122 grams" which is
"52.34%" weight reduction.
2. All stresses are under allowable stress in structural analysis.
3. From the set of values, the best outcomes are found at deformation is 0.014503 mm, stress 92.09MPa and temperature at
93.296 C on AL-7075 T6 with 5 mm thickness

11. REFERENCES
[1] K K Dhande , N I Jamadar and Sandeep Ghatge July 2014 “DESIGN AND ANALYSIS OF COMPOSITE BRAKE PEDAL: AN
ERGONOMIC APPROACH”, International Journal of Mechanical Engineering and Robotics Research (IJMERR), Volume 3(3), pp.
474–482.
[2] Nand Mangukia and Nandish Mangukia 2018 “Design and Fabrication of Brake Pedal for All Terrain Vehicle
“,INTERNATIONAL JOURNAL OF ENGINEERING DEVELOPMENT AND RESEARCH (IJEDR), Volume 6(2), pp. 562 – 568 .
[3] Miss. ASHWINI N.GAWANDE, Prof.G.E.KONDHALKAR, and Prof. ASHISH R.PAWAR , May -2017 “STATIC STRUCTURAL
ANALYSIS AND OPTIMIZATION OF BRAKE PEDAL”, International Research Journal of Engineering and Technology (IRJET),
Volume: 04(5), pp. 3222-3227.
[4] MIM Sargini , SH Masood , Suresh Palanisamy , Elammaran Jayamani and Ajay Kapoor , “Finite element analysis of
automotive arm brake pedal for rapidmanufacturing”, IOP Conference Series: Materials Science and Engineering,
doi:10.1088/1757-899X/715/1/012020.
[5] Degenstein, Thomas, Winner, Hermann, “Dynamic Measurement of the Forces in the Friction Area of a Disc Brake during a
Braking process”, Vol.2, pp.19, 2006.
[2] Akshat Sharma, Amit Kumar Marwah, “Braking Systems: Past, Present & Future”, Vol. 2, Issue- 3, pp.29-31, March- 2013
ISSN - 2250-1991
[3] K. Sowjanya, S. Suresh, “Structural Analysis of DiscBrakeRotor”,International Journal ofComputerTrendsand Technology
(IJCTT), Vol.4 Issue 7–July 2013

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