Disc brake system is one of the most critical components in a vehicle, which is always exposed to nonlinear transient thermoelastic conditions. Optimal design of a brake system to suit the heat transfer, weight and packing requirements is an ongoing challenge. Substantial researches have been carried out and are underway, in order to address the diverse issues related to thermal, mechanical and structural performances of automobile disc brakes. With the extensive application of numerical tools and techniques, the analyses involved became easier and effective. The present article provides an exhaustive review of the numerical and experimental studies reported so far, on the analysis and design of solid and ventilated disc brakes. The directions for future works are also described. The review reveals that, there is enough scope for extended research for realizing optimal design of disc brake system by truly emulating all the relevant practical situations.

Thermo-Mechanical and Structural Performances of Automobile Disc Brakes: A Review of Numerical and Experimental Studies

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.

https://www.mdpi.com/2504-477X/7/6/244/pdf?version=1686567778

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

A disc brake rotor includes a core including a hat-shaped section, an annular inboard mounting surface, and an annular outboard mounting surface axially spaced from the inboard mounting surface and connected to the inboard mounting surface. The hat-shaped section has a central mounting face and a cylindrical shoulder extending from a periphery of the mounting face. The outboard mounting surface has an interior peripheral edge radially spaced from the shoulder, and the inboard mounting surface has an interior peripheral edge engaged to the shoulder. An inboard friction ring includes radially extending first projections secured to the inboard mounting surface. The outboard friction ring includes radially extending second projections secured to the outboard mounting surface. The first projections are angularly aligned with the second projections. The first and second projections extend into the space between the inboard and outboard mounting surfaces and have a gap therebetween.

High performance disc brake rotor

In today’s developing automobile sector, there is drastic change in the technology from transmission system to braking system. The braking system is considered as one of the most important system from performance as well as safety point of view. When the brakes are applied to the moving vehicle, all the kinetic energy of the vehicle gets converted into equivalent amount of heat generation. Disc brake is the recent trend in automobile vehicles which dissipates the heat faster than the conventional drum brakes. but if hard braking is done, there is induction of thermal stresses in the brake disc which leads to generation of excessive temperature .If this heat is not dissipated properly, then distortion will be get produced in the disc which leads to thermal cracking of the disc leading to disc failure. The brake disc has an inherent ability that there is no change of co-efficient of friction on the disc so there is no problem of brake fading phenomenon. The main advantage of disc brake is that only a small portion of the disc is in contact with the friction material i.e. the caliper. Hence there is large surface area of the disc which can dissipate the heat to the atmosphere. Specifically the heat dissipated to the atmosphere is the forced convection mode. The aim of this research work is to choose best profile and best material which can dissipate maximum amount of heat to the surrounding. The models of disc are created in Creo parametric 2.0 while the analysis is conducted in ANSYS 15.0.the analysis performed in ANSYS is steady state thermal.

https://www.jetir.org/papers/JETIR1806604.pdf

Analysis of Vented Disc Brake By Using Software

In today’s developing automobile sector, there is drastic change in the technology from transmission system to braking system. The braking system is considered as one of the most important system from performance as well as safety point of view. When the brakes are applied to the moving vehicle, all the kinetic energy of the vehicle gets converted into equivalent amount of heat generation. The brake disc has an inherent ability that there is no change of co-efficient of friction on the disc so there is no problem of brake fading phenomenon. Disc brake is the recent trend in automobile vehicles which dissipates the heat faster than the conventional drum brakes. but if hard braking is done, there is induction of thermal stresses in the brake disc which leads to generation of excessive temperature .If this heat is not dissipated properly, then distortion will be get produced in the disc which leads to thermal cracking of the disc leading to disc failure. The main advantage of disc brake is that only a small portion of the disc is in contact with the friction material i.e. the caliper. Hence there is large surface area of the disc which can dissipate the heat to the atmosphere. Specifically the heat dissipated to the atmosphere is the forced convection mode. The aim of this research work is to choose best profile and best material which can dissipate maximum amount of heat to the surrounding. The models of disc are created in Creo parametric 2.0 while the analysis is conducted in ANSYS 15.0.the analysis performed in ANSYS is steady state thermal.

Analysis of ventilated disc brake through software

The motive of undertaking the project of “Coupled Thermal and Structural Analysis of Brake Disc Rotor manufactured from AMMC” is to study and evaluate the performance of brake disc rotor under severe braking conditions A brake is a device by means of which an artificial frictional resistance is applied to a moving machine member in order to stop the motion of the machine Generally, cast iron is used to manufacture brake disc rotor, but AMMC is selected considering crucial advantages of the AMMC over cast iron material AMMC refers to a class of light weight high performance Aluminium centric material systems As silicon carbide is added in the AMMC as a reinforcement, it reinforces the overall mechanical and thermal properties of the AMMC The objective of coupled analysis is to investigate the temperature distribution and heat flux across the brake disc and to couple its effects with structural analysis to check the validity of the disc brake rotor under thermal and structural load The model of the brake disc rotor is developed by using solid modelling software Creo Parametric 20 Further the analysis is done by using ANSYS Workbench

Coupled Thermal and Structural Analysis of Brake Disc Rotor Manufactured from Aluminum Metal Matrix Composite (AMMC) reinforced with Silicon Carbide

This paper deals with the   manufacturing of disc brake rotor using AMMC. AMMC is the combination of aluminium and silicon carbide along with small quantity of other material like magnesium, aluminium oxide, graphite which are added in precise quantity to enhance the chemical, mechanical and thermal strength of material. The whole process is carried out in controlled environment. Gravity die casting is the suitable process used for the purpose. Pre-processing of additives are carried out precisely. Stir casting is one of the economical and extensively used methods to enhance attractive properties of AMC’s. This paper presents an overview of stir casing process, process parameter and preparation of AMC using aluminium alloy as matrix phase and alumina (Al2O3) as reinforcement

Manufacturing of Disc Brake Rotor Using Aluminium Metal Matrix Composite (AMMC) reinforced with Silicon Carbide

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Coupled Thermal and Structural Analysis of Brake Disc Rotor Manufactured from Aluminum Metal Matrix Composite (AMMC) reinforced with Silicon Carbide

Manufacturing of Disc Brake Rotor Using Aluminium Metal Matrix Composite (AMMC) reinforced with Silicon Carbide