Design and Structural Analysis of Disc Brake by using CATIA and ANSYS-WORKBENCH

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 04 Issue: 09 | Sep -2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 70
DESIGN AND STRUCTURAL ANALYSIS OF DISC BRAKE BY USING CATIA
AND ANSYS-WORKBENCH
Sunkara Sreedhar1, Parosh.G2
1 PG Scholar,Mechanical Engineering,Chadalawada Ramanamma Engineering College, Tirupati,
Andhra Pradesh,India.
2 Asst.Professor,Mechanical Engineering,Chadalawada Ramanamma Engineering College, Tirupati,
Andhra Pradesh,India.
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Abstract:- The disc brake is a device for slowing or stopping
the rotation of a wheel. Friction causes the disc and attached
wheel to slow or stop. Brakes convert friction to heat, but if the
brakes get too hot, they will cease to work because they cannot
dissipate enough heat. This condition of failure is known as
brake fade. Disc brakes are exposed to large thermal stresses
during routine braking and extra ordinary thermal stresses
during hard braking. Actual disc brake has no holes; design is
changed by giving holes in the disc break for more heat
dissipation. An attempt is made in this project work to
modeling and analysis of disc break first the disc break is
modeling and meshing by using catia V5R20 and static and
modal analysis is done by ANSYS 14.0 software by using four
different materials like mildsteel, Aluminium, Castiron and
composite material (e-glass).
Our main aim of the project is to compare the four
materials which is having least deformation and less frequency
and choose the best material which is suitablefor designingthe
disc brake.
Keywords:CATIA,ANSYS WORKBENCH, mildsteel,
Aluminium, Castiron and composite material (e-glass).
1. INTRODUCTION
Brake is a device by means of artificial frictional resistance
applied to moving machine member, in order to stop the
motion of vehicle. The energy absorbed by brakes is
dissipated in the form of heat. This heat is dissipated in the
form of atmosphere.
2. PRINCIPLES OF BRAKING SYSTEM
When brakes are applied, hydraulically actuated pistons
move the friction pads into contact with the disc applying
equal and opposite forces on the disc. Due to the friction in
between disc and pad surfaces, the kinetic energy of the
rotating wheel is converted into heat which vehicle is to stop
after a certain distance.
Figure 1 : Working principle of disc brake
2.1. COMPONENTS OF DISCBRAKE
 CALLIPER
 HUB
 BRAKEPAD
 PISTON MASTER
 CYLINDER
Figure 2 : Components of disc brake
CALLIPER : A disc brake consists of a cast iron disc bolted to
the wheel hub and a stationary housing called caliper.
HUB : It is the central part of the wheel, rotating on or with
the axle and from which the spokes radiate.
BRAKEPAD : It is a thin block of friction producing material
that presses against a vehicle brake discorrotortoenable the
wheel to stop.

PISTON : A disc or cylindrical part tightly fitting and moving
within a cylinder either to compress the cylinder or
expanding inside the cylinder into a rectilinear motion
usually transformed into rotary motion by means of a
connecting rod.
MASTER CYLINDER : It converts force to pressure. Pressure
is used to move brake pads into the place.
2.2. TYPES OF DISCBRAKES
 FIXED CALLIPER
 FLOATING CALLIPER
 SLIDING CALLIPER
FIXED CALLIPER : It uses one or more pistons mounted on
each side of rotor .The caliper is mountedrigidlyanddoes not
move.
Figure 3 : Floating Calliper
FLOATING AND SLIDING CALLIPER : Both designs arequite
similar and are lumped together.Thecaliper whichisnot held
in a fixed position, moves slightly bringing the outside pad
into contact with rotor. The most common type of disc brake
in modern cars is single floating caliper.
Figure 4 : Sliding Calliper
3. LITERATURE REVIEW
Talati and Jalalifar et al. (2009), presented a paper on
Analysis of heat conduction in a disk brake system. In this
paper, the governing heat equations for the disk and the pad
are extracted in the form of transient heat equations with
heat generation that is dependant to time and space. In the
derivation of the heat equations, parameters such as the
duration of braking, vehicle velocity, geometries and the
dimensions of the brake components, materials of the disk
brake rotor and the pad and contact pressure distribution
have been taken into account. The problem is solved
analytically using Green's function approach. It is concluded
that the heat generated due to friction between the disk and
the pad should be ideally dissipated to the environment to
avoid decreasing the friction coefficient betweenthedisk and
the pad and to avoid the temperature rise of various brake
components and brake fluid vaporization due to excessive
heating.
Rotor Disc of Disc Brake by using new materials to
improve braking efficiency and provide greater stability to
vehicle. An attempt has been made to investigate the suitable
hybrid composite material which is lighter than cast iron and
has good Young’s modulus, Yield strength and density
properties. Aluminum base metal matrix compositeand High
Strength Glass Fibercompositeshavea promisingfrictionand
wear behavior as a Disk brake rotor. The transient thermo
elastic analysis of Disc brakes in repeated brake applications
has been performed and the results were compared. Finally
concluded that the suitable material forthe brakingoperation
is S2 glass fiber and all the values obtained from the analysis
are less than their allowable values and brake Disc design is
safe based on the strength and rigidity criteria
Telang A K, Rehman A, and Dixit G,Das S et.al (2013)
investigated on alternate materials in automobile brake disc
applications with emphasis on aluminium composites and
have obtained the results that the friction coefficient of AMC
is 25-30% times that of cast Iron and better wear
characteristics ,the thermal conductivity of AMC can be two
or three times higher than cast iron. An MMC disc could be 60
% lighter than an equivalent cast iron component. The
Thermal Diffusivity, which is the rate of heat dissipation
compared to that of storage, is four times that of castiron.
4. METHODOLOGY
CATIA is mechanical design software. It is a feature-based,
parametric solid modeling design tool thattakesadvantageof
the easy-to-learn Windows graphical user interface. You can
create fully associative 3-D solid models with or without
constraints while utilizing automatic or user-defined
relations to capture design intent. To further clarify this
definition, the italic terms above will be further defined.

Figure 5 : CATIA model of Disc Brake
4.1 Modelling of a Propeller:
Pad: On exit of sketcher mode the feature is to be padded
(adding material)
Pocket: On creation of basic structure further pocket has to
be created (removing material)
Revolve: Around axis the material is revolved, the structure
should has same profile around axis.
Rib: sweeping uniform profile along trajectory (adding
material)
Slot: sweeping uniform profile along trajectory (removing
material)
Loft: Sweeping non-uniform/uniform profile on different
plane along linear/non-linear trajectory
4.2 Fundamentals of FEA:
The finite element methodisnumerical analysistechniquefor
obtaining approximate solutions to a wide variety of
engineering problems. Because of its diversity and flexibility
as an analysis tool, it is receiving much attention in almost
every industry. In more and more engineering situations
today, we find that it is necessary to obtain approximate
solutions to problem ratherthanexactclosedformsolution.It
is not possible to obtain analytical mathematical solutionsfor
many engineering problems. An analytical solutions is a
mathematical expression that gives the values of the desired
unknown quantity at anylocationinthebody,asconsequence
it is valid for infinite number of location in the body. For
problems involving complex material properties and
boundary conditions, the engineer resorts to numerical
methods that provide approximate, but acceptable solutions.
The finite element method has become a powerful tool forthe
numerical solutions of a wide range of engineeringproblems.
It has been developed simultaneously withtheincreasing use
of the high- speed electronic digital computers and with the
growing emphasis on numerical methods for engineering
analysis. This method started as a generalization of the
structural idea to some problems of elastic continuum
problem, started in terms of different equations.
4.3 Meshing of Propeller Blade:
The solid model is transfer to the ANSYS WORKBENCH
software.with the required commanding the mesh is
generated for the model.Generally there two types of meshes
are there ther are Tetrahedral Mesh.
(i) Hexahedral Mesh
The Tetrahedral mesh is a polygon consists of four triangular
faces three of them are meet at a pointcalled as vertex.It has
6edges and 4 vertices.In case of hexahedral mesh it has 12
edges and 8 vertices.For the accuracy of the solution
hexahedral gives the exact result.In the ANSYS software the
internal command setting can be available for mesh
generation.
Figure 6 : Fine meshed model of Disc Brake
4.4 Structrural Analysis:
Structural analysis is the most common application of the
finite element analysis. The term structural implies civil
engineering structure such as bridge and building, but also
naval, aeronautical and mechanical structure such as ship
hulls, aircraft bodies and machine housing as well as
mechanical components such as piston, machine parts and
tools.

4.4.1 MILD STEEL MATERIAL
Figure 7 : Modal Analysis of Mild Steel
Figure 8 : Modal Analysis of Mild Steel with Pre-Stresses
Figure 9 : Modal Analysis of Mild Steel without Pre-
Stresses
4.4.2 ALUMINIMUM MATERIAL
Figure 10 : Modal Analysis of Aluminimum
Figure 11 : Modal Analysis of Aluminimum with Pre-
Stresses
Figure 12 : Modal Analysis of Aluminimum without Pre-
Stresses

4.4.3 CAST IRON MATERIAL
Figure 13 : Modal Analysis of Cast Iron
Figure 14 : Modal Analysis of Cast Iron with Pre-Stresses
Figure 15 : Modal Analysis of Cast Iron without Pre-
Stresses
4.4.4 COMPOSITE MATERIAL
Figure 16 : Modal Analysis of Composite Material
Figure 17 : Modal Analysis of Composite Material with Pre-
Stresses
Figure 18 : Modal Analysis of Composite Material without
Pre-Stresses

5. Results & Discussions
6. CONCLUSIONS :
It is concluded from the above study that using CATIAV5 R20
software design and modeling become easier. Only few steps
are needed to make drawing in three dimensions, some can
be imported to Ansys for analysis. Disc brake made of four
different materials mild steel, all alloy, cast iron and
composite material (e-glass) are analysed. Max pressure is
found at the centre of disc brake. This is equal for all
materials.
The disc brake is done on both static structural and modal
analysis (with and without pre stresses). Depending upon on
frequency and pressure values, the max frequency and
pressure is found at Al alloy, and minimum frequency and
pressure is found at composite material.
By comparing the above table, mild steel frequency and
pressure will varies but the mild steel has good corrosive
resistanceand the aluminimum valuesalsoincreasingslightly
but it has good thermal conductivity and the cast iron has
good strength.
From the four materials e-glasshasgoodpropertiesandit has
less frequency and less deformation. So, e-glass is the best
material for designing the disc brake. Although e-glass has
less deformation but it is costlier. If we reduce the cost of e-
glass it is more economical to use with long life. Hence,
composite material is suitable material for designing disc
brake.
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