IJSTE - International Journal of Science Technology & Engineering | Volume 3 | Issue 08 | February 2017

ISSN (online): 2349-784X

Design and Analysis of Disc Brake and Caliper of

Four Wheeler
Dr. A. Satyanarayana Reddy Shaik Mudassir Mohiddin
Professor ((IIT-M), M.S(USA), PhD (OU)) BE Student
Department of Mechanical Engineering Department of Mechanical Engineering
Muffakham Jah College of Engineering and Technology, Muffakham Jah College of Engineering and Technology,
Hyderabad, India Hyderabad, India

Syed Uzair Ul Hasan Syed Sajjad Ali Anas

BE Student BE Student
Department of Mechanical Engineering Department of Mechanical Engineering
Muffakham Jah College of Engineering and Technology, Muffakham Jah College of Engineering and Technology,
Hyderabad, India Hyderabad, India

Abstract
In an automobile, the brakes play a bigger role to decelerate the vehicle, and it also acts as a safety component. Without the braking
system, the passenger in a vehicle will be unsafe. Therefore, there must be the proper braking system. This work deals with the
study of the existing braking component and designs new braking components using SOLID WORKS to do stress analysis and
temperature developed during panic braking. The analysis was done on brake disc of three different materials using ANSYS
workbench. The dimensions are taken from existing MARUTI 800.The results are plotted graphically such that the effective
braking to be obtained.
Keywords: Maruti, Solid Works, Ansys, Braking Effort, Deceleration, Stopping Distance, Stress Analysis, Thermal
Analysis
________________________________________________________________________________________________________

I. INTRODUCTION

As the modern automobile technology has been stepped ahead to increase the speed and performance, the important thing is to
stop the vehicle in the desired place or to decelerate the vehicle in the reasonable safe distance. This deceleration process will
generate an enormous amount of heat, which is the conversion of vehicle kinetic energy into heat energy due to rubbing action
between disc plate (rotor) and brake pad. The brakes should be capable of withstanding the force developed while braking, as the
road conditions, will vary and at critical braking or panic braking. At this point, the maximum force will be generated on brake
caliper and mounting of brake mechanical components. Calipers are a vital part of the braking system which works due to hydraulic
pressure generated by pressing the brake pedal in the master cylinder. Brake Caliper squeezes the brake pads against the surface
of the brake disc. The brake caliper uses nonviscous and high boiling point which gets heated up due to friction between pads and
disc.
Continuous usage of the brakes will generate heat which may melt the rotor as the material is limited to some extent.To overcome
this problem, we even use different coatings on the rotor to increase the material properties which increase the rotors life.
This project will review the analysis of the braking system of the modern automobile, through which we will design the brake
rotor, and caliper for analysis of the force developed. Heat generated and dissipated while the brakes are operated, and list the
different material of rotor so that vehicle will achieve the minimum stopping distance and good effective braking.

II. LITERATURE SURVEY

Rudolf Lampert's Brake Design and Safety second edition in temperature analysis [3.1], During braking, the kinetic and potential
energies of a moving vehic1e are converted into thermal energy through friction in the brakes, In a single stop with high heat
generation, i.e., high deceleration levels, the braking time may be less than the time required for the heat to penetrate Through rotor
material. Under these conditions, no convective brake cooling occurs, and all braking energy is assumed ten be absorbed by the
brake and lining. t_b=(L^2/5 k/c)
AR Daudi, M Narains CAE predictions and experiment verification [3.1], The CFD and FEA meshes are created in the solid
(rotor) and fluid (air) region. Steady state conjugate heat transfer CFD analysis is performed to obtain flow and temperature
distribution in both the solid and fluid region. The heat transfer coefficient is extracted from the CFD results and used as boundary
conditions for the transient heat transfer FEA. The FEA is used to predict transient temperature distribution because it reduces the
computational time significantly and further analysis can be done to predict thermal stresses and distortion, which cannot currently
be done in CFD.

All rights reserved by www.ijste.org 186

 Design and Analysis of Disc Brake and Caliper of Four Wheeler
(IJSTE/ Volume 3 / Issue 08 / 032)

D ANDERSON, A WIRTH and S McCLURE's Thermally sprayed surface coatings suitable for use in automotive brake and
clutch applications[4.0], This investigation has provided encouraging data that indicates that thermally sprayed metal matrix
coatings can be used to great effect to enhance the life of cast iron components in automotive braking applications. Friction
materials producing similar or better friction performance than seen when paired with cast iron have been found to produce lower
disc and pad wear when rubbed against specific ferrous coatings. The challenge now is to produce a cost effective coating free
from stress relief cracking that will appeal to the whole of the automotive industry rather than niche markets such as sports car
racing and the luxury end of the market.

III. CALCULATIONS

Design Calculations
Mass of the Vehicle: 1000 kg
Velocity of the Vehicle (v): 54 kmph
Input driver Force: 343.35N
Pedal ratio: 7:1
Pedal Effort: 245N
Master Cylinder Bore Dia: 19.1mm
Disc Diameter: 284mm
Disc Effective Radius ( ): 0.129 m
Caliper Piston Dia: 50mm
Friction Btw Rotor and Pad ( ): 0.4 to 0.5
Friction between road and tire: 0.62
Force in Master cylinder = Pedal Force*Pedel Ratio = 2403.45N
Pressure in Master cylinder = Force/Area = 8.38 Mpa
Laden radius of the tyer (R) = 0.072 m

Brake Torque (T) = = 17553.46 N-m

Where r is radius ratio of wheel and rotor

Clamping load (C) = = 151192.59 N


Overall System Pressure = = 77 Mpa

2
Stopping Distance at 54 kmph =
2
= 18.50 m
Deceleration / Braking time = 3 s

Energy Calculations
Energy generated during Braking
1
K.E = 2
2
= 14580 J
.
Braking Power =

=48600 W

Heat flux (Q) =

= 991836.347 Watt/2
The analysis is done by taking the dynamic load distribution between front and rear as 53.89:46.81
Heat flux on front Wheels = 534500 Watt/2
Heat flux on Rear Wheels = 250199 Watt/2
The temperature rise at the time of braking can be calculated by
0.527
= +
. .
The convection film coefficient as a function of vehicle speed, v, uses the following formula
0.037
= . 0.8 . 0.33

Convection film coefficient can be calculated numerically or through CFD analysis.

All rights reserved by www.ijste.org 187

 Design and Analysis of Disc Brake and Caliper of Four Wheeler
(IJSTE/ Volume 3 / Issue 08 / 032)

Analysis and Results

Meshed part of the disc, with fine size and relevance of 40.

Fig. 1: Meshed part of the disc

The force from Both Sides in time steps:

Table - 1
Force from Both Sides in time steps
Steps Time [s] Force [N]
0
1 0
1
2 2 5400
3 3 10800
4 4 16200
5 5 21600
6 6 27000
7 7 32400
8 8 37800
9 9 43200
10 10 48600
11 11 54000
12 12 59400
13 13 64800
14 14 70200
15 15 75600

Fig. 2: Total Deformation Fig. 3: Graph

The above graph and figure show the total deformation in the disc at the time of braking with the maximum deformation of
5.047x103and minimum deformation of 1.55x10-3

All rights reserved by www.ijste.org 188

 Design and Analysis of Disc Brake and Caliper of Four Wheeler
(IJSTE/ Volume 3 / Issue 08 / 032)

Fig. 4: Total Deformation Fig. 5: Strain developed

The above images show the maximum stress developed in the disc. The maximum stress developed is 53.372 Mpa and minimum
stress developed is 1.04x10-2 Mpa.
The above results are shown in the table.
Table 2
Results
Total Deformation (mm) Equivalent Strain (mm/mm) Equivalent Stress (MPa)
Minimum 1.55e-003 7.94e-008 1.04e-002
Maximum 5.047e-003 3.73e-004 53.372

Fig. 6: Brake Disc Thermal Analysis

Table 3
Results
Total Deformation (0C) Equivalent Strain (W/m2)
Minimum 53.121 1412.6
Maximum 429.19 2.014e+006
Table 4
Results
Steps Time [s] Pressure [Mpa]
0
1 1
1
2 2 6.423
3 3 11.852
4 4 17.281
5 5 22.71
6 6 28.139
7 7 33.568
8 8 38.997
9 9 44.426
10 10 49.855
11 11 55.284
12 12 60.713
13 13 66.142
14 14 71.571
15 15 77

All rights reserved by www.ijste.org 189

 Design and Analysis of Disc Brake and Caliper of Four Wheeler
(IJSTE/ Volume 3 / Issue 08 / 032)

Fig. 7: Meshed part of the caliper with the relevance of 40.

Table 5
Results
Total Deformation (mm) Equivalent Strain (mm/mm) Equivalent Stress (MPa)
Minimum 0 4.41e-008 5.49e-003
Maximum 0.4172 9.01e-004 1315.7

IV. CONCLUSION

The main conclusion drawn from the program of the work reported in this paper are as follows:
1) The structural analysis is carried out by applying the Gradual Increment Clamping force on the periphery of the brake pads
and velocity has been applied while braking.
2) Thermal analysis is carried out by applying the Heat Flux on the circumference of the pad and the convection film coefficient
was applied to the overall surface of the disc as convection occurs on the overall surface.
3) The Structural analysis is done on the Brake Caliper where the pressure will increase and the deformation is observed.

REFERENCES
[1] Brake Design and Safety (Second Edition) Rudolf Limpert
[2] ISBN 1-56091-915-9 1. Automobiles-Brakes- Design and Construction
[3] Limpcrt. R., "Temperature and Stress Analysis of Solid-Rotor Disc Brakes," Ph.D. Dissertation, University of Michigan. 1972.
[4] Anwar R. Daudi and Wes E. Dickerson, "Disc Brake Rotor Design for Increased Airflow," 15th SAE Brake Colloquium, October 8, 1997
[5] A R DAUDI and M NARAIN, CAE prediction and experimental verification of maximum temperature of cool running 72 curve fin brake rotor design.
[6] D ANDERSON, A WIRTH and S McClure Thermally sprayed surface coatings suitable for use in automotive brake and clutch applications.

All rights reserved by www.ijste.org 190