Brake Disc Design And Analysis

Presentation 1

In the first presentation weve completed the following targets

1. All theoretical calculations required for brake components selection.
2. Initial materials research to look for different materials available to
use for manufacturing of a brake disc
3. 1st thermal analysis of brake disc using few given assumptions
BRAKE CALCULATIONS

Assumed Wheelbase = 1550mm

Assumed Height of CG of car= 250mm
Static load distribution = 50:50
Weight of Vehicle = 300kg
Coefficient of Friction at tire-ground interface u = 1.6
Selected wheels and tires = 13inch rims and 260mm tire radius
At maximum deceleration of 1.6g the dynamic weight distribution is found
to =210:90kg= 70:30 weight distribution
Disk Selected= 220mm on front and 200mm on rear
Assumed Brake Pad size= 3.875 cm height, 4cm width.
Most calculations done by hand so shown seperately

Thermal Analysis Logic-

Brake Disc Design And Analysis

Presentation 1

As on braking all the kinetic energy is converted into heat energy- which is
generated at the brake pad-disc interface we will distribute this as heat
power supplied at the disc pad interface.
Well determine kinetic energy by assuming a given speed, lets say 25m/s
to be brought to a complete stop given by 0.5*mass*velocity^2.. The max
coefficient of friction would provide us with the stopping time, so wed know
how the power is distributed over time.
Wed analyze the disk under this heat power provided as a flux only for the
while the brakes are applied, and convection throughout the rest of the disk
surface so it is simultaneously also cooling reflecting a real scenario. Initial
temperature is assumed to be same as the surroundings
The solidworks simulation is prepared and will be shown separately.

MATERIAL SELECTION

Brake Disc Design And Analysis

Presentation 1

The most commonly used materials are cast iron and stainless steel
Aluminium matrix compounds are are rarely used as the only upside is
weight reduction, they have lower coefficient of friction and although there
ar special compositions which do not suffer from quick wear by having
enough strength, they cannot be recommended for high temperature
applications.
Carbon-Ceramic composites are ideal for high load use but as their
working temperatures are too high and are a high cost alternative they are
beyond the scope of our project and we will be neglecting them here.
Cast Iron is the common choice due to high strength, high hardness, high
temperature strength but they are let down by low corrosion resistance and
relatively lower coefficient of friction achievable by use of specialized brake
pad materials such as sintered steel pads which give better performance
with stainless steel.

Stainless SteelsThe major challenge for a material to be used as a brake disc are given
and well tackle them one by one to reach an ideal material
1 Hardness- A brake disc is generally expected to have high hardness for
slower wear rates. The hardness generally required is about 32-38 HRC
(Rockwell hardness)
2 Temper Softening- As in braking applications the temperature reached
are often as high as 400 degrees temper softening( a property of a metal to
soften due to tempering and subsequent change in its microstructure at
those temperatures) might lead to warping and deformation of disc under
the physical loads.
3 Strength- The strength of the material should be high to withstand the
loads and this is measured in terms of its yield/compressive strength

Brake Disc Design And Analysis

Presentation 1

4 Fatigue Strength- As it is a component that is supposed to work for a

long time of application depending on the use, its expected to work without
failure for large number of cycles. This is measured in terms of creep
strength
5 High Temperature Surface Oxidation

From some research on the internet over stainless steel grades- We

eliminated all grades except Austenitic and Martensitic steels due to poor
strength

OTHER IDEAL PHYSICAL PROPERTIES

High Conductivity- As surface temperatures run high in brake disc

applications , for even distribution of temperature which will lead to even
wear, similar behavior and less chances of warping.

GRADES USED IN INDUSTRY

Mainly martensitic steels with grades EN403, 410 and 420 are used,
known as 13% Cr steels
Stability is a crucial factor as the properties of the material shouldnt
change with use
*Adding Cu to the steel increases the possibility of faster cooling rates
during hardening of discs, which is restricted due to change in flatness due
to faster cooling methods(0.5 to 2.5%)
Mo is added to increase corrosion resistance but its an expensive
alternative

Brake Disc Design And Analysis

Presentation 1

Well compare few Grades such as Austenitic vs Martensitic (Series 3XX vs

4XX)
Ideal Composition from RP01 is 12%Cr, 1.5%Mn, 0.13%Nb, 0.05%C, 0.04
%N
Addition of N and Nb increases temper softening.

Comparison of 316, 321, 403, 410 and 420