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Computer Aided Design and Analysis of Disc Brake Rotors Pandya Nakul Amrish* BITS Pilani, Dubai Campus, Dubai International Academic City (DIAC), Dubai, UAE

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Computer Aided Design and Analysis of Disc Brake Rotors Pandya Nakul Amrish* BITS Pilani, Dubai Campus, Dubai International Academic City (DIAC), Dubai, UAE mo uto bile A E in n g s i n Amrish, Adv Automob Eng 2016, 5:2 e c e e n Advances in Automobile r a i n v DOI: 10.4172/2167-7670.1000144 g d A ISSN: 2167-7670 Engineering Research Article Open Access Computer Aided Design and Analysis of Disc Brake Rotors Pandya Nakul Amrish* BITS Pilani, Dubai Campus, Dubai International Academic City (DIAC), Dubai, UAE Abstract The purpose of this research is to analyze different types of disc brake rotors, which are commonly used in automobile industry and to propose a new design of brake rotor. Analysis of brake rotor includes Structural analysis and Steady state Thermal analysis for each design. A comparison between the existing brake rotors and proposed new design is carried out and based on the results the best design is found out by ANSYS software. Keywords: Mechanical device; Electrical devices; Disc brake rotors; better stopping performance and at the same time are safer and cost Heat energy efficient, the incorporation of 4 wheel Disc brakes have been increased from the former front Disc brakes and rear drum brakes system. Introduction However, the drum type brakes are better at performance when the Brakes are mechanical or sometimes electrical devices or mass of the automobile increases, and thus, drum brakes are common components that help to decelerate the vehicle and eventually stop in heavy automobiles (Figure 1). the vehicle in a certain time and certain distance called the stopping Pumping brakes: As the name suggests, pumping brakes are used distance or the braking distance. The automotive brake is basically where a pump is already one of the components of equipment or the a mechanical device which inhibits motion, slowing or stopping machinery system. For example, an internal-combustion piston motor a moving object, here, the automobile, and thereby preventing its can have the fuel supply stopped, and then internal pumping losses motion [1]. Brakes are one of the most significant safety systems in of the engine create some braking. Pumping brakes dump energy any automobile. Functioning of brakes is based on the conservation of losses into heat energy. At times, some pumping brakes can act as energy. Most commonly used brakes are frictional brakes, where the regenerative brakes that can recharge a pressure reservoir called the friction produced between two objects convert the kinetic energy of the hydraulic accumulator. moving vehicle into heat energy. Electromagnetic brakes: Here, again, as the name goes, Theory of brakes Electromagnetic brakes are equipped in systems in which an electric motor is pre-installed. For instance, hybrid gasoline and electrical Frictional brakes: Friction brakes are the most commonly automobiles use an electrical motor for the purpose of battery charging. employed braking system in commercial or special purpose vehicles. This motor is in turn used as a regenerative brake. Electromagnetic They generally are rotating devices with a rotating wear surface like brakes or Electro-mechanical brakes, as formerly referred, retard or Disc or drum and a stationary pad or a shoe. Here, the kinetic energy of the moving vehicle is utilized to stop the vehicle by conversion of this kinetic energy into heat energy/frictional energy [2]. A few common configurations of this type of braking are disc brakes, drum brakes and hydrodynamic brakes. Disc brakes: Shoes or pads contract and provide compressive frictional force on the outer surface of a rotating Disc. It is a circular metal Disc on which the pads are mounted. Usually it is made up of cast iron material. The design of Disc brakes is varied depending on the application, amount of exposure, thermal properties of the material and the amount of heat dissipation required when brakes are applied and the total mass to be stopped [3]. This project report will contain the design of a Disc brake rotor, and analyze results of Structural and Thermal Analysis at a later stage. Figure 1: Types of brakes – disc and drum. Drum brakes: Shoes or lining expand and rub against the inside surface of a rotating drum. Drum is again made up of cast iron material and mounted in the wheel hub in such a manner that the liner pads *Corresponding author: Amrish PN, BITS Pilani, Dubai Campus, Dubai attach themselves to the inner surface of the drum and during the International Academic City (DIAC), Dubai, UAE, Tel: +971 4 420 0700; E-mail: [email protected] braking process, the shoe or brake lining expand or move outwards, due to the cam and spring action, to attach themselves to the brake Received April 06, 2016; Accepted May 25, 2016; Published May 31, 2016 drum which provides friction and causes the drum to retard or stop Citation: Amrish PN (2016) Computer Aided Design and Analysis of Disc Brake its rotating motion. Drums are usually heavier than Disc brakes and Rotors. Adv Automob Eng 5: 144. doi:10.4172/2167-7670.1000144 occupy significantly more space due the lining and drum it and hence Copyright: © 2016 Amrish PN. This is an open-access article distributed under its application in commercial vehicles is somewhat restricted [4]. the terms of the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original author and Generally it is noticed and observed that Disc brakes provide a source are credited. Adv Automob Engg ISSN:2167-7670 AAE, an open access journal Volume 5 • Issue 2 • 1000144 Citation: Amrish PN (2016) Computer Aided Design and Analysis of Disc Brake Rotors. Adv Automob Eng 5: 144. doi:10.4172/2167-7670.1000144 Page 2 of 13 stop the motion using electromagnetic force which applies a mechanical resistance or friction. The working principle of the electromagnetic brake is based on an electric retarder. This electric retarded works on the creation of eddy currents [5]. Electromagnetic brakes also use metal Discs or drums. The eddy currents are generated within the metal Disc or drum rotating between two electromagnets. These generated eddy currents set up a force opposite to the direction of the rotating Disc/ drum. When the electromagnet is energized, retardation of the rotating element takes place and as a result heat energy is produced in the process of electromagnetic energy absorption. The braking is directly proportional to the generation of the current. More the current, higher the braking torque. Figure 3: Working of hydraulic brakes. Major applications of this type of braking are in trains, trams, industrial electric motors and robotic applications. Recent to the actual braking mechanism which is located near the wheels of developments and innovations in designs have made the use of the vehicle. electromagnetic brakes possible even in aircraft industries (Figure 2). The most common arrangement of hydraulic brakes consists of the Working of electromagnetic brakes following: Engagement: Electromechanical brakes work through an electric (i) A lever or a brake pedal activation, however transmit torque mechanically. At the point when (ii) Pushrod or actuating rod voltage/current is provided, the curl is energized making an attractive field. This transforms the curl into an electromagnet that creates (iii) Master cylinder assembly attractive lines of flux. The attractive flux pulls in the armature to the (iv) Hydraulic lines substance of the brake. The armature and center are typically mounted on the pole (client supplied) that is turning. Since the brake loop is (v) Brake caliper assembly mounted decidedly, the brake armature, center and shaft arrive at a Working of hydraulic brakes: As the driver presses the brake stop in a short measure of time [6]. pedal or the lever, the push rod exerts a force called the braking Disengagement: When current/voltage is withdrawn from force on the pistons placed in the brake master cylinder located just the brake, the armature becomes free to turn along with the shaft. behind the brake pedal of the vehicle causing the brake fluid to flow Armature is held by the springs away from the brake surface as the into the pressure chamber [8]. Consequently, overall pressure in the power is released and a small air gap is created [7]. entire system increases which in turn forces the fluid to flow through hydraulic lines, which are nothing but pipes through which through Cycling: Cycling is obtained by turning the voltage/current to the which the fluid can easily flow, towards one or more calipers based on coil on and off. Slippage should occur only during deceleration. When the hydraulic braking system design. The calipers are also designed the brake is engaged, there should be no slippage once the brake comes accordingly that sufficient force is applied to the Discs or drums to to a full stop. provide required frictional force for braking (Figure 3). Hydraulic brakes: This type of braking system is one of the basic types of braking and as per its name; this braking system uses a fluid Theory of Disc Brakes called the brake fluid for its braking mechanism. Ethylene Glycol is one Introduction to disc brakes common and most typically used brake fluid. The brake fluid helps in transferring pressure applied by the operator/driver on the brake pedal Fredrick William Lanchester, a Birmingham car maker, designed the first Disc brakes in 1902. This first design, the original design, was made in such a way that there were two Discs that pressed against each other to generate friction and slow down a moving vehicle. Only in 1949, production of Disc brakes was incorporated and acknowledged by the automotive industries. Disc brakes are a two-part system, first being Disc/rotor and the second being the brake caliper assembly. One or sometimes more hydraulic action pistons are a part of the caliper assembly that push against the back of a brake pad thereby, clamping them around the spinning or the rotating Disc/rotor from both the sides.
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