Design of high performance automotive

brake caliper using ANSYS

Rafael Blumberg Author
Nicolino Foschini Neto Co-author

PRESENTATION TOPICS
Formula FEI Overview;
Problem Description;
Goals;
Methodology;

Conclusion and next steps.

Formula FEI Team

Formula SAE student competition

Problem Description
Mass comparison

410g

810g
1210g

10% of mass reduction

680g
1360g

Problem Description
Loads distribution

N d 1 a W

Normal force on front axis [N]

2071.29 N

Deceleration [gs]

1.6 gs

Vehicle weight [N]

2550 N

Ratio C.G. height / wheel base

0.226

Rear weight distribution

54.9 %

Normal force on rear axis

478.71 N

N t ( a) W

Problem Description
Brake loads

Td

N d Dp

Brake torque [Nm]

378.8 Nm

Friction tire/road coefficient

1.6

Tire rolling diameter [m]

0.457 m

Line Pressure [MPa]

4.0 MPa

Piston area [mm]

1279.41 mm

Brake factor (2 * pad/disc)

0.8

Theorical effective radius [m]

0.0925 m

Td
Pd *
Re BF Ae

Problem Description
Loads distribution

Problem Description
Loads distribution

Cut view to analyze

the forces

Problem Description
Loads distribution

Pressure = 4 MPa

Normal disc force

reaction

Causing by
pressure

Problem Description
Loads distribution

Another cut view to

analyze the forces

Problem Description
Loads distribution

Tangential disc
force

Causing by
Torque (380 Nm)

Friction = 0.4

Problem Description
Effective radius

Problem Description
Effective radius

Re

Goals
Designing the caliper to the selected position

Mass reduction

Improve rigidity

Determine effective radius

Methodology
Create the mesh

184250 elements was used with 289923 nodes to mesh generation and 4 Gb
of RAM memory was needed to solve.

Methodology
Verifying mesh quality (aspect ratio)

Methodology
Verifying mesh quality (aspect ratio)

Methodology
Create contact regions

Methodology
Create contact regions pad / brake disc

This contact is responsible to transform pressure in torque

Methodology
Create contact regions piston / pad

This contact determine how much force is transferred to body

and how much remains on pin

Methodology
Create contact regions piston / body

This contact is important because it is the unique contact that holds the
brake disc at its position, and also, it is responsible to set calipers efficiency
and piston solicitation

Methodology
Double check contact regions gaps and penetrations

Methodology
Pressures, torques and supports

Methodology
Pressures, torques and supports

Cylindrical support used with

tangential and axial free,
because at this simulation was
used fixed caliper and floating
disc

Methodology
Pressures, torques and supports

Compression only support was selected to give a real condition at holes,

although it requires more process time

Methodology
Pressures, torques and supports

This displacement needed be used to hold the caliper on axial holes direction
because compression only support give that freedom

Methodology
Pressures, torques and supports

380 Nm moment applied, same value

as calculated at begin based on
vehicle characteristics

Methodology
Pressures, torques and supports

4 MPa pressure applied at every piston case, fluid line

and pistons

Methodology
Double check reaction torque at same surface that was
applied brake torque

Methodology
Double check reaction torque at same surface that was
applied brake torque
Was applied 380 Nm, but was obtained 338 Nm.

380
X

-------------------------------

338
380

Torque necessary to be applied is 426 Nm in order to obtain 380 Nm as real

applied

Methodology
Double check reaction torque at same surface that was
applied brake torque

Conclusion and next steps

Results (Equivalent Stress All bodies)

Conclusion and next steps

Results (Equivalent Stress All bodies)

Conclusion and next steps

Results (Total Deformation All bodies)

Conclusion and next steps

Results (Equivalent Stress Body)

Conclusion and next steps

Results (Z deformation Body)

Conclusion and next steps

Results (Z deformation Body)

Conclusion and next steps

Results (Equivalent Stress Pads)

Conclusion and next steps

Results (Equivalent Stress Piston)

Conclusion and next steps

Results (Equivalent Stress Pins)

Conclusion and next steps

Results (Contact Pressure Pad / Disc)

Conclusion and next steps

Its possible to analyze a brake caliper with good precision
without to need a high level computer
Start simulation with thermical DOF using friction heat
generation

THANKS

Prof. Dr. Roberto Bortolussi