Fea Project Report

FEA PROJECT REPORT
OPTIMISATION OF NUMBER OF HOLES IN THE

DISC BRAKE BASED ON THERMAL AND
STRUCTURAL ANALYSIS
BY
ALLEN GEORGE (201603)
FEBIN JOSEPH THOMAS (201623)
STEVE MERICK GEORGE (201624)
ADITYA KALASKAR (201630)
ABSTRACT
Braking system represents one of the most fundamental safety critical components in
modern vehicles. Brake absorbs kinetic energy of the rotating parts (Wheels) and the energy
is dissipated in the form of heat energy to the surrounding atmosphere. It decelerates or
stops the vehicle. When brake is applied to the disc brake it is subjected to high stress, thus
it may suffer structural and wear issues. Hence for the better performance, structural, stress
and the thermal analysis is preferred to choose low stress material. 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 calliper. 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
objective of this paper is to model and analyse stress concentration, structural deformation
and thermal gradient of disc brake. Here the disc brake is designed by using Solidworks 16
and analysis is done by ANSYS workbench R 16.0.
Key words: Solidworks, ANSYS, Disc Brake, FEA (Finite Element Analysis), Thermal stress,
Temperature Gradient Distribution, Structural Error, Equivalent Stress, Total Heat Flux
INTRODUCTION
A brake is a device which uses frictional resistance to stop motion of machine or vehicle.
The brakes absorb kinetic energy and dissipate it as heat energy. Brake systems must
have following requirements:
 Vehicle must stop within a minimum distance in emergency.
 Braking properties must not fade with constant prolonged application.
 It must have anti wear properties.

[1] Figure 1 Source: Google.com, Disc Brake Assembly
Disc brake is an important component of vehicle retardation system. It is the type of
brake that uses callipers to squeeze pairs of pads against a disc to create friction. That
friction slows the rotation of a shaft (vehicle axle) to hold it stationary or slow its
rotational speed. Disc brake is usually made of cast iron or ceramic composite such as
carbon, aluminium, and silica. Friction material known as brake pad is made to engage
on both side of disc either mechanically or pneumatically. This friction material causes
disc to slowdown or stop. The disc brake is sandwiched between two pads activated by
a cylinder backed in a calliper mounted on the stud shaft. At the point where the brake
lever is pressed, pressurised hydraulic pressed fluid is constrained in the chamber
pushing the contradicting cylinders and brake parts. When the pad is pressed against
the disc, the brake absorbs kinetic energy of the vehicle and it is transferred into heat
which is mainly absorbed by rotor and brake pad. This heat is dissipated into the
surrounding atmosphere. Due to the generation of frictional heat on the interface of
the disc and pad, there is rise in temperature. When this temperature exceeds the
critical value of the given material, it leads to catastrophic events such as brake fail,
premature wear, and failure of bearing, thermal crack or vaporisation of brake fluid.
Furthermore, due to heat generation at the disc pad interface, global deformation
occurs in disc and pad. Some common deformations are coning and buckling
Mainly three types of mechanical stress are subjected on disc brake.
 Traction force, caused by centrifugal effect and it occurs when wheel is rotating and no
brake force is applied to the disc.
 Compressive force, when the brake is applied due to action of the force, exerted by
pressing the pad perpendicular onto the surface of the disc.
 Due to braking action caused by rubbing on the brake pad against the surface of the disc.
It acts in opposite direction of the disc rotation.
The effect of the pressure distribution plays a vital role. Uniform pressure distribution
between pad and the rotor leads to uniform pad wear and even friction coefficient. On the
other hand, non-uniform pressure distribution may lead to uneven wear and it’s called disc
brake squeal. Frictional heat generated between two sliding bodies is responsible for
thermo-elastic deformation which ultimately alters the contact pressure distribution. In
order to predict the temperature distribution, many investigations had been carried out on
heat generation phenomenon between contact surfaces in brake. Due to the characteristic
pressure sliding speed, coefficient of viscosity this process is very complex. Finite element
analysis is used to solve it. From experimental setup it has been found out that coefficient of
viscosity generally decreases with increasing sliding speed and applied load but increases
with increasing disc temperature of 230 degree and then decreases with above disc
temperature. Furthermore specific wear rate was found to increase with increase in sliding
speed and disc temperature.
FINITE ELEMENT METHOD (FEM)

It is a numerical technique for finding the approximate solutions to boundary value
problems for partial differential equations. It uses subdivision of a whole problem
domain into simpler part, called finite elements and solve the problem by minimizing
an associated error function. The subdivision of the whole domain has several
advantages:-
I. Accurate representation of the complex geometry.
II. Inclusion of dissimilar material property.
III. Easy representation of the solution.
IV. Capture of the local effects. It divides the domain into a group of sub domain; every
sub domain is represented by a set of element equations of the original domain.
1) INPUT PARAMETERS
MATERIAL DATA
 TITANIUM ALLOY
TABLE 29
Titanium Alloy > Constants
Density 4.62e-006 kg mm^-3
Coefficient of Thermal Expansion 9.4e-006 C^-1
Specific Heat 5.22e+005 mJ kg^-1 C^-1
Thermal Conductivity 2.19e-002 W mm^-1 C^-1
Resistivity 1.7e-003 ohm mm
TABLE 31
Titanium Alloy > Compressive Yield Strength
Compressive Yield Strength MPa
930
TABLE 32
Titanium Alloy > Tensile Yield Strength
Tensile Yield Strength MPa
930
TABLE 33
Titanium Alloy > Tensile Ultimate Strength
Tensile Ultimate Strength MPa
1070
TABLE 34
Titanium Alloy > Isotropic Secant Coefficient of Thermal Expansion
Reference Temperature C
22
TABLE 35
Titanium Alloy > Isotropic Elasticity
Temperature C Young's Modulus MPa Poisson's Ratio Bulk Modulus MPa Shear Modulus MPa
96000 0.36 1.1429e+005 35294

TABLE 36
Titanium Alloy > Isotropic Relative Permeability
Relative Permeability
a) BRAKE DISC 1 (WITHOUT HOLES)

GEOMETRY
TABLE 2
Model (A4, B4) > Geometry
Object Name Geometry
State Fully Defined
Definition
C:\Users\R\Desktop\DESIGN\PROJECT\DISC
Source
BRAKE_files\dp0\SYS\DM\SYS.agdb
Type DesignModeler
Length Unit Meters
Element Control Program Controlled
Display Style Body Color
Bounding Box
Length X 300. mm
Length Y 300. mm
Length Z 5. mm
Properties
Volume 2.4004e+005 mm³
Mass 1.109 kg
Scale Factor Value 1.
Statistics
Bodies 1
Active Bodies 1
Nodes 64941
Elements 39226
Mesh Metric None
Basic Geometry Options
Parameters Yes
Parameter Key DS
Attributes No
Named Selections No
Material Properties No
Advanced Geometry Options
Use Associativity Yes
Coordinate Systems No
Reader Mode Saves

No
Updated File
Use Instances Yes
Smart CAD Update No
Compare Parts On Update No
Attach File Via Temp File Yes
Temporary Directory C:\Users\R\AppData\Local\Temp
Analysis Type 3-D
Decompose Disjoint
Yes
Geometry
Enclosure and Symmetry

Yes
Processing
TABLE 3
Model (A4, B4) > Geometry > Parts
Object Name Solid
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
Stiffness Behavior Flexible
Coordinate System Default Coordinate System
Reference Temperature By Environment
Material
Assignment Titanium Alloy
Nonlinear Effects Yes
Thermal Strain Effects Yes
Bounding Box
Length X 300. mm
Length Y 300. mm
Length Z 5. mm
Properties
Mass 1.109 kg
Centroid X -1.6096e-006 mm
Centroid Y 2.6401e-004 mm
Centroid Z 2.5 mm
Moment of Inertia Ip1 7619.6 kg·mm²
Moment of Inertia Ip3 15235 kg·mm²
Statistics
Nodes 64941
Elements 39226
Mesh Metric None
MESH
TABLE 5
Model (A4, B4) > Mesh
Object Name Mesh
State Solved
Display
Defaults
Physics Preference Mechanical
Relevance 0
Sizing
Use Advanced Size Function Off
Relevance Center Coarse
Element Size Default

Initial Size Seed Active Assembly
Smoothing Medium
Transition Fast
Span Angle Center Coarse
Minimum Edge Length 0.542410 mm
Inflation
Use Automatic Inflation None
Inflation Option Smooth Transition
Transition Ratio 0.272
Maximum Layers 5
Growth Rate 1.2
Inflation Algorithm Pre
View Advanced Options No
Patch Conforming Options
Triangle Surface Mesher Program Controlled
Patch Independent Options
Topology Checking No
Advanced
Number of CPUs for Parallel Part Meshing Program Controlled
Shape Checking Standard Mechanical
Element Midside Nodes Program Controlled
Straight Sided Elements No
Number of Retries Default (4)
Extra Retries For Assembly Yes
Rigid Body Behavior Dimensionally Reduced
Mesh Morphing Disabled
Defeaturing
Pinch Tolerance Please Define
Generate Pinch on Refresh No
Automatic Mesh Based Defeaturing On
Defeaturing Tolerance Default

Statistics
Nodes 64941
Elements 39226
Mesh Metric None
TABLE 6
Model (A4, B4) > Mesh > Mesh Controls
Object Name Refinement
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 23 Faces
Definition
Suppressed No
Refinement 3
STEADY-STATE THERMAL
TABLE 7
Model (A4, B4) > Analysis
Object Name Steady-State Thermal (A5)
State Solved
Definition
Physics Type Thermal
Analysis Type Steady-State
Solver Target Mechanical APDL
Options
Generate Input Only No
TABLE 8
Model (A4, B4) > Steady-State Thermal (A5) > Initial Condition
Object Name Initial Temperature
State Fully Defined
Definition
Initial Temperature Uniform Temperature

Initial Temperature Value 30. °C
TABLE 9
Model (A4, B4) > Steady-State Thermal (A5) > Analysis Settings
Object Name Analysis Settings
State Fully Defined
Step Controls
Number Of Steps 1.
Current Step Number 1.
Step End Time 1. s
Auto Time Stepping Off
Define By Substeps
Number Of Substeps 5.
Solver Controls
Solver Type Program Controlled
Solver Pivot Checking Program Controlled
Radiosity Controls
Radiosity Solver Program Controlled
Flux Convergence 1.e-004
Maximum Iteration 1000.
Solver Tolerance 1.e-007 W/mm²
Over Relaxation 0.1
Hemicube Resolution 10.
Nonlinear Controls
Heat Convergence Program Controlled
Temperature Convergence Program Controlled
Line Search Program Controlled
Output Controls
Calculate Thermal Flux Yes
General Miscellaneous No
Store Results At All Time Points
Analysis Data Management

C:\Users\R\Desktop\DESIGN\PROJECT\DISC
Solver Files Directory
BRAKE_files\dp0\SYS\MECH\
Future Analysis None
Scratch Solver Files

Directory
Save MAPDL db No
Delete Unneeded Files Yes
Nonlinear Solution Yes
Solver Units Active System
Solver Unit System nmm
TABLE 10
Model (A4, B4) > Steady-State Thermal (A5) > Loads
Object Name Temperature Convection Radiation
State Fully Defined
Scope
Geometry 2 Faces 86 Faces 87 Faces
Definition
Type Temperature Convection Radiation
Magnitude 450. °C (ramped)
Suppressed No
Film Coefficient 6.e-005 W/mm²·°C (ramped)
Ambient Temperature 30. °C (ramped)
Convection Matrix Program Controlled
Correlation To Ambient
Emissivity 0.8 (step applied)

FIGURE 1
Model (A4, B4) > Steady-State Thermal (A5) > Temperature
FIGURE 2
Model (A4, B4) > Steady-State Thermal (A5) > Convection
TABLE 11
Model (A4, B4) > Steady-State Thermal (A5) > Convection
Steps Time [s] Convection Coefficient [W/mm²·°C] Temperature [°C]
0. 0.
1 30.
1. 6.e-005
FIGURE 3
Model (A4, B4) > Steady-State Thermal (A5) > Radiation
STATIC STRUCTURAL
TABLE 18
Model (A4, B4) > Analysis
Object Name Static Structural (B5)
State Solved
Definition
Physics Type Structural
Analysis Type Static Structural
Options
Environment Temperature 22. °C

TABLE 19
Model (A4, B4) > Static Structural (B5) > Analysis Settings
State Fully Defined
Step Controls
Number Of Steps 1.
Step End Time 1. s
Define By Substeps
Solver Controls
Weak Springs Program Controlled
Large Deflection Off
Inertia Relief Off
Restart Controls
Generate Restart Points Program Controlled
Retain Files After Full

No
Solve
Nonlinear Controls
Newton-Raphson Option Program Controlled
Force Convergence Program Controlled
Moment Convergence Program Controlled
Displacement
Program Controlled
Convergence
Rotation Convergence Program Controlled
Stabilization Off
Output Controls
Stress Yes
Strain Yes
Nodal Forces No
Contact Miscellaneous No
C:\Users\R\Desktop\DESIGN\PROJECT\DISC BRAKE_files\dp0\SYS-
1\MECH\

Directory
Save MAPDL db No
Nonlinear Solution No
TABLE 20
Model (A4, B4) > Static Structural (B5) > Loads
Object Name Fixed Support Pressure Pressure 2
State Fully Defined
Scope
Geometry 12 Faces 1 Face
Definition
Type Fixed Support Pressure
Suppressed No
Define By Vector
Magnitude 1. MPa (ramped)
Direction Defined
FIGURE 7
Model (A4, B4) > Static Structural (B5) > Pressure
FIGURE 8
Model (A4, B4) > Static Structural (B5) > Pressure 2
b) BRAKE DISC 2 (WITH HOLES)
GEOMETRY
TABLE 2
Model (C4, D4) > Geometry
Object Name Geometry
State Fully Defined
Definition
Source
2\DM\SYS-2.agdb
Type DesignModeler
Length Unit Meters
Element Control Program Controlled

Bounding Box
Length X 300. mm
Length Y 300. mm
Length Z 5. mm
Properties
Mass 0.88221 kg
Scale Factor Value 1.
Statistics
Bodies 1
Active Bodies 1
Nodes 463189
Elements 282690
Mesh Metric None
Basic Geometry Options
Parameters Yes
Parameter Key DS
Attributes No
Named Selections No
Material Properties No
Advanced Geometry Options
Use Associativity Yes
Coordinate Systems No
Reader Mode Saves

No
Updated File
Use Instances Yes
Smart CAD Update No
Compare Parts On Update No
Attach File Via Temp File Yes
Temporary Directory C:\Users\R\AppData\Local\Temp
Analysis Type 3-D

Decompose Disjoint
Yes
Geometry
Enclosure and Symmetry

Yes
Processing
TABLE 3
Model (C4, D4) > Geometry > Parts
Object Name Solid
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
Stiffness Behavior Flexible
Coordinate System Default Coordinate System
Reference Temperature By Environment
Material
Assignment Titanium Alloy
Nonlinear Effects Yes
Thermal Strain Effects Yes
Bounding Box
Length X 300. mm
Length Y 300. mm
Length Z 5. mm
Properties
Mass 0.88221 kg
Centroid X 3.35e-003 mm
Centroid Y -5.9924e-004 mm
Centroid Z 2.5 mm

Moment of Inertia Ip3 11156 kg·mm²
Statistics
Nodes 463189
Elements 282690
Mesh Metric None
MESH
TABLE 5
Model (C4, D4) > Mesh
Object Name Mesh
State Solved
Display
Defaults
Physics Preference Mechanical
Relevance 100
Sizing
Use Advanced Size Function Off
Relevance Center Fine
Element Size Default
Initial Size Seed Active Assembly
Smoothing Medium
Transition Fast
Span Angle Center Fine
Minimum Edge Length 3.99420 mm
Inflation
Use Automatic Inflation None
Inflation Option Smooth Transition
Transition Ratio 0.272
Maximum Layers 5
Growth Rate 1.2
Inflation Algorithm Pre

View Advanced Options No
Patch Conforming Options
Triangle Surface Mesher Program Controlled
Patch Independent Options
Topology Checking No
Advanced
Number of CPUs for Parallel Part Meshing Program Controlled
Shape Checking Standard Mechanical
Element Midside Nodes Program Controlled
Straight Sided Elements No
Number of Retries Default (4)
Extra Retries For Assembly Yes
Rigid Body Behavior Dimensionally Reduced
Mesh Morphing Disabled
Defeaturing
Pinch Tolerance Please Define
Generate Pinch on Refresh No
Automatic Mesh Based Defeaturing On
Defeaturing Tolerance Default
Statistics
Nodes 463189
Elements 282690
Mesh Metric None
TABLE 6
Model (C4, D4) > Mesh > Mesh Controls
Object Name Refinement
State Fully Defined
Scope
Geometry 23 Faces
Definition
Suppressed No
Refinement 3
STEADY-STATE THERMAL
TABLE 7
Model (C4, D4) > Analysis
Object Name Steady-State Thermal (C5)
State Solved
Definition
Physics Type Thermal
Analysis Type Steady-State
Options
TABLE 8
Model (C4, D4) > Steady-State Thermal (C5) > Initial Condition
Object Name Initial Temperature
State Fully Defined
Definition
Initial Temperature Uniform Temperature
Initial Temperature Value 30. °C
TABLE 9
Model (C4, D4) > Steady-State Thermal (C5) > Analysis Settings
State Fully Defined
Step Controls
Number Of Steps 1.
Step End Time 1. s
Define By Substeps
Solver Controls
Radiosity Controls
Radiosity Solver Program Controlled
Flux Convergence 1.e-004
Maximum Iteration 1000.
Solver Tolerance 1.e-007 W/mm²
Over Relaxation 0.1
Hemicube Resolution 10.
Nonlinear Controls
Heat Convergence Program Controlled
Temperature Convergence Program Controlled
Output Controls
Calculate Thermal Flux Yes
2\MECH\

Directory
Save MAPDL db No
Nonlinear Solution Yes

TABLE 10
Model (C4, D4) > Steady-State Thermal (C5) > Loads
Object Name Temperature Convection Radiation
State Fully Defined
Scope
Geometry 2 Faces 247 Faces
Definition
Type Temperature Convection Radiation
Magnitude 450. °C (ramped)
Suppressed No
Film Coefficient 6.e-005 W/mm²·°C (ramped)
Ambient Temperature 30. °C (ramped)
Convection Matrix Program Controlled
Correlation To Ambient
Emissivity 0.8 (step applied)
FIGURE 1
Model (C4, D4) > Steady-State Thermal (C5) > Temperature
FIGURE 2
Model (C4, D4) > Steady-State Thermal (C5) > Convection
TABLE 11
Model (C4, D4) > Steady-State Thermal (C5) > Convection
Steps Time [s] Convection Coefficient [W/mm²·°C] Temperature [°C]
0. 0.
1 30.
1. 6.e-005
FIGURE 3
Model (C4, D4) > Steady-State Thermal (C5) > Radiation
STATIC STRUCTURAL
TABLE 18
Model (C4, D4) > Analysis
Object Name Static Structural (D5)
State Solved
Definition
Physics Type Structural
Analysis Type Static Structural
Options
Environment Temperature 22. °C
TABLE 19
Model (C4, D4) > Static Structural (D5) > Analysis Settings
State Fully Defined
Step Controls
Number Of Steps 1.
Step End Time 1. s
Define By Substeps
Solver Controls
Weak Springs Program Controlled
Large Deflection Off
Inertia Relief Off
Restart Controls
Generate Restart Points Program Controlled
Retain Files After Full

No
Solve
Nonlinear Controls
Newton-Raphson Option Program Controlled
Force Convergence Program Controlled
Moment Convergence Program Controlled
Displacement
Program Controlled
Convergence
Rotation Convergence Program Controlled
Stabilization Off
Output Controls
Stress Yes
Strain Yes
Nodal Forces No
Contact Miscellaneous No
3\MECH\

Directory
Save MAPDL db No
Nonlinear Solution No
TABLE 20
Model (C4, D4) > Static Structural (D5) > Loads
Object Name Fixed Support Pressure Pressure 2
State Fully Defined
Scope
Geometry 12 Faces 1 Face
Definition
Type Fixed Support Pressure
Suppressed No
Define By Vector
Magnitude 1. MPa (ramped)
Direction Defined
FIGURE 7
Model (C4, D4) > Static Structural (D5) > Pressure
FIGURE 8
Model (C4, D4) > Static Structural (D5) > Pressure 2
2) RESULT AND ANALYSIS
a) BRAKE DISC 1 (WITHOUT HOLES)
STEADY-STATE THERMAL SOLUTION

TABLE 12
Model (A4, B4) > Steady-State Thermal (A5) > Solution
Object Name Solution (A6)
State Solved
Adaptive Mesh Refinement
Max Refinement Loops 1.
Refinement Depth 2.
Information
Status Done
Post Processing
Calculate Beam Section Results No
TABLE 13
Model (A4, B4) > Steady-State Thermal (A5) > Solution (A6) > Solution Information
Object Name Solution Information
State Solved
Solution Information
Solution Output Solver Output
Update Interval 2.5 s
Display Points All
FE Connection Visibility
Activate Visibility Yes
Display All FE Connectors
Draw Connections Attached To All Nodes
Line Color Connection Type
Visible on Results No
Line Thickness Single

Display Type Lines
TABLE 14
Model (A4, B4) > Steady-State Thermal (A5) > Solution (A6) > Results
Object Name Temperature Total Heat Flux Thermal Error
State Solved
Scope
Geometry All Bodies
Definition
Type Temperature Total Heat Flux Thermal Error
By Time
Display Time Last
Calculate Time History Yes
Identifier
Suppressed No
Results
Minimum 38.47 °C 2.3476e-005 W/mm² 3.5471e-007
Maximum 451.04 °C 0.34085 W/mm² 88012
Minimum Value Over Time
Minimum 38.47 °C 1.5422e-006 W/mm² 6.6121e-008
Maximum 44.711 °C 2.3476e-005 W/mm² 4.0101e-007
Maximum Value Over Time
Minimum 114.08 °C 5.3076e-002 W/mm² 681.02
Maximum 451.04 °C 0.34085 W/mm² 88012
Information
Time 1. s
Load Step 1
Substep 5
Iteration Number 10
Integration Point Results
Display Option Averaged

Average Across Bodies No
FIGURE 4
Model (A4, B4) > Steady-State Thermal (A5) > Solution (A6) > Temperature
TABLE 15
Model (A4, B4) > Steady-State Thermal (A5) > Solution (A6) > Temperature
Time [s] Minimum [°C] Maximum [°C]
0.2 44.711 114.08
0.4 44.545 198.23
0.6 42.466 282.44
0.8 40.322 366.71
1. 38.47 451.04
FIGURE 5
Model (A4, B4) > Steady-State Thermal (A5) > Solution (A6) > Total Heat Flux
TABLE 16
Model (A4, B4) > Steady-State Thermal (A5) > Solution (A6) > Total Heat Flux
Time [s] Minimum [W/mm²] Maximum [W/mm²]
0.2 1.5422e-006 5.3076e-002
0.4 5.1523e-006 0.12277
0.6 1.0413e-005 0.19602
0.8 1.6759e-005 0.26919
1. 2.3476e-005 0.34085
FIGURE 6
Model (A4, B4) > Steady-State Thermal (A5) > Solution (A6) > Thermal Error
TABLE 17
Model (A4, B4) > Steady-State Thermal (A5) > Solution (A6) > Thermal Error
Time [s] Minimum Maximum
0.2 6.6121e-008 681.02
0.4 2.2237e-007 5185.4
0.6 3.3813e-007 17782
0.8 4.0101e-007 43494
1. 3.5471e-007 88012
STATIC STRUCTURAL SOLUTION

TABLE 23
Model (A4, B4) > Static Structural (B5) > Solution
Object Name Solution (B6)
State Solved
Refinement Depth 2.
Information
Status Done
Post Processing
TABLE 24
Model (A4, B4) > Static Structural (B5) > Solution (B6) > Solution Information
State Solved
Newton-Raphson Residuals 0
Display Points All
Display Type Lines
TABLE 25
Model (A4, B4) > Static Structural (B5) > Solution (B6) > Results
Object Name Total Deformation Equivalent Stress Structural Error
State Solved
Scope
Geometry All Bodies
Definition
Type Total Deformation Equivalent (von-Mises) Stress Structural Error
By Time
Display Time Last
Identifier
Suppressed No
Results
Minimum 0. mm 0.72542 MPa 7.0826e-008 mJ
Maximum 0.52133 mm 900.88 MPa 24.857 mJ
Maximum 0. mm 0.72542 MPa 7.0826e-008 mJ
Minimum 0.10427 mm 180.18 MPa 0.99427 mJ
Maximum 0.52133 mm 900.88 MPa 24.857 mJ
Information
Time 1. s
Load Step 1
Substep 5
Iteration Number 5

FIGURE 9
Model (A4, B4) > Static Structural (B5) > Solution (B6) > Total Deformation
TABLE 26
Model (A4, B4) > Static Structural (B5) > Solution (B6) > Total Deformation
Time [s] Minimum [mm] Maximum [mm]
0.2 0.10427
0.4 0.20853
0.6 0. 0.3128
0.8 0.41706
1. 0.52133
FIGURE 10
Model (A4, B4) > Static Structural (B5) > Solution (B6) > Equivalent Stress
TABLE 27
Model (A4, B4) > Static Structural (B5) > Solution (B6) > Equivalent Stress
Time [s] Minimum [MPa] Maximum [MPa]
0.2 0.14508 180.18
0.4 0.29016 360.35
0.6 0.43525 540.53
0.8 0.58033 720.7
1. 0.72542 900.88
FIGURE 11
Model (A4, B4) > Static Structural (B5) > Solution (B6) > Structural Error
TABLE 28
Model (A4, B4) > Static Structural (B5) > Solution (B6) > Structural Error
Time [s] Minimum [mJ] Maximum [mJ]
0.2 2.8331e-009 0.99427
0.4 1.1333e-008 3.9771
0.6 2.5498e-008 8.9484
0.8 4.5331e-008 15.908
1. 7.0826e-008 24.857
b) BRAKE DISC 2 (WITH HOLES)
STEADY-STATE THERMAL SOLUTION

TABLE 12
Model (C4, D4) > Steady-State Thermal (C5) > Solution
Object Name Solution (C6)
State Solved
Refinement Depth 2.
Information
Status Done
Post Processing
TABLE 13
Model (C4, D4) > Steady-State Thermal (C5) > Solution (C6) > Solution Information
State Solved
Display Points All
Display Type Lines
TABLE 14
Model (C4, D4) > Steady-State Thermal (C5) > Solution (C6) > Results
Object Name Temperature Total Heat Flux Thermal Error
State Solved
Scope
Geometry All Bodies
Definition
Type Temperature Total Heat Flux Thermal Error
By Result Set Time
Set Number 1.
Identifier
Suppressed No
Display Time Last
Results
Minimum 44.527 °C 8.0813e-005 W/mm² 1.7059e-009
Maximum 114. °C 0.32751 W/mm² 10764
Minimum 38.277 °C 8.0567e-006 W/mm² 2.7256e-010
Maximum 44.527 °C 8.0813e-005 W/mm² 1.7257e-009
Minimum 114. °C 5.1338e-002 W/mm² 67.222
Maximum 450. °C 0.32751 W/mm² 10764

Information
Time 0.2 s 1. s
Load Step 1
Substep 1 5
Iteration Number 2 8
FIGURE 4
Model (C4, D4) > Steady-State Thermal (C5) > Solution (C6) > Temperature
TABLE 15
Model (C4, D4) > Steady-State Thermal (C5) > Solution (C6) > Temperature
Time [s] Minimum [°C] Maximum [°C]
0.2 44.527 114.
0.4 44.304 198.
0.6 42.219 282.
0.8 40.118 366.
1. 38.277 450.
FIGURE 5
Model (C4, D4) > Steady-State Thermal (C5) > Solution (C6) > Total Heat Flux
TABLE 16
Model (C4, D4) > Steady-State Thermal (C5) > Solution (C6) > Total Heat Flux
Time [s] Minimum [W/mm²] Maximum [W/mm²]
0.2 8.0567e-006 5.1338e-002
0.4 8.2864e-006 0.11842
0.6 3.6213e-005 0.18868
0.8 3.1007e-005 0.2592
1. 8.0813e-005 0.32751
FIGURE 6
Model (C4, D4) > Steady-State Thermal (C5) > Solution (C6) > Thermal Error
TABLE 17
Model (C4, D4) > Steady-State Thermal (C5) > Solution (C6) > Thermal Error
Time [s] Minimum Maximum
0.2 2.7256e-010 67.222
0.4 9.1157e-010 553.53
0.6 1.5658e-009 2016.5
0.8 1.7257e-009 5064.7
1. 1.7059e-009 10764
STATIC STRUCTURAL SOLUTION

TABLE 23
Model (C4, D4) > Static Structural (D5) > Solution
Object Name Solution (D6)
State Solved
Refinement Depth 2.
Information
Status Done
Post Processing
TABLE 24
Model (C4, D4) > Static Structural (D5) > Solution (D6) > Solution Information
State Solved
Newton-Raphson Residuals 0
Display Points All
Display Type Lines
TABLE 25
Model (C4, D4) > Static Structural (D5) > Solution (D6) > Results
Object Name Total Deformation Equivalent Stress Structural Error
State Solved
Scope
Geometry All Bodies
Definition
Type Total Deformation Equivalent (von-Mises) Stress Structural Error
By Time
Display Time Last 1. s
Identifier
Suppressed No
Results
Maximum 0.47498 mm 806.95 MPa 0.22354 mJ
Maximum 0. mm 0.50541 MPa 3.9973e-010 mJ
Minimum 9.4997e-002 mm 161.39 MPa 8.9414e-003 mJ
Maximum 0.47498 mm 806.95 MPa 0.22354 mJ
Information
Time 1. s
Load Step 1
Substep 5
Iteration Number 5

FIGURE 9
Model (C4, D4) > Static Structural (D5) > Solution (D6) > Total Deformation
TABLE 26
Model (C4, D4) > Static Structural (D5) > Solution (D6) > Total Deformation
Time [s] Minimum [mm] Maximum [mm]
0.2 9.4997e-002
0.4 0.18999
0.6 0. 0.28499
0.8 0.37999
1. 0.47498
FIGURE 10
Model (C4, D4) > Static Structural (D5) > Solution (D6) > Equivalent Stress
TABLE 27
Model (C4, D4) > Static Structural (D5) > Solution (D6) > Equivalent Stress
Time [s] Minimum [MPa] Maximum [MPa]
0.2 0.10108 161.39
0.4 0.20216 322.78
0.6 0.30324 484.17
0.8 0.40433 645.56
1. 0.50541 806.95
FIGURE 11
Model (C4, D4) > Static Structural (D5) > Solution (D6) > Structural Error
TABLE 28
Model (C4, D4) > Static Structural (D5) > Solution (D6) > Structural Error
Time [s] Minimum [mJ] Maximum [mJ]
0.2 1.5989e-011 8.9414e-003
0.4 6.3956e-011 3.5766e-002
0.6 1.439e-010 8.0473e-002
0.8 2.5583e-010 0.14306
1. 3.9973e-010 0.22354
CONCLUSION
On comparing a disc brake with holes and without holes, the
final temperatures after heat dissipation with an initial
condition of 450°C are found to be 38.277°C and 38.47°C
respectively and that for equivalent stresses are 806.95 MPa
and 900.88 MPa respectively which is below the ultimate
tensile limit (i.e. 930MPa). The following observations clearly
states that the design for disc brakes with holes are much
better than that without holes and that both of them won’t
fail in any of the above conditions.
REFERENCES
[1] V. Chengal Reddy, M. Gunasekhar Reddy, Dr. G. Harinath
Gowd, Modeling and Analysis of FSAE Car Disc Brake Using FEM,
ISSN 2250-2459, 3(9), September 2013.
[2] Praveena S, Lava Kumar M, Sreekanth Reddy S, Modeling and
Structural Analysis of Disc Brake, ISSN: 2319-8753, 3(10) October
2014.
[3] V. Chengal Reddy, M. Gunasekhar Reddy, Dr. G. Harinath
Gowd, Modeling and Analysis of FSAE Car Disc Brake Using FEM,
ISSN 2250-2459, Volume 3, Issue 9, September 2013.

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FEA PROJECT REPORT

OPTIMISATION OF NUMBER OF HOLES IN THE

 Vehicle must stop within a minimum distance in emergency.

 Braking properties must not fade with constant prolonged application.

 It must have anti wear properties.

FINITE ELEMENT METHOD (FEM)

Coefficient of Thermal Expansion 9.4e-006 C^-1

Specific Heat 5.22e+005 mJ kg^-1 C^-1

Thermal Conductivity 2.19e-002 W mm^-1 C^-1

Resistivity 1.7e-003 ohm mm

96000 0.36 1.1429e+005 35294

a) BRAKE DISC 1 (WITHOUT HOLES)

State Fully Defined

Length Unit Meters

Element Control Program Controlled

Display Style Body Color

Volume 2.4004e+005 mm³

Scale Factor Value 1.

Mesh Metric None

Basic Geometry Options

Use Associativity Yes

Reader Mode Saves

Use Instances Yes

Smart CAD Update No

Compare Parts On Update No

Attach File Via Temp File Yes

Temporary Directory C:\Users\R\AppData\Local\Temp

Analysis Type 3-D

Enclosure and Symmetry

Stiffness Behavior Flexible

Coordinate System Default Coordinate System

Reference Temperature By Environment

Assignment Titanium Alloy

Nonlinear Effects Yes

Thermal Strain Effects Yes

Volume 2.4004e+005 mm³

Moment of Inertia Ip1 7619.6 kg·mm²

Moment of Inertia Ip2 7619.6 kg·mm²

Moment of Inertia Ip3 15235 kg·mm²

Mesh Metric None

Display Style Body Color

Physics Preference Mechanical

Use Advanced Size Function Off

Relevance Center Coarse

Element Size Default

Span Angle Center Coarse

Minimum Edge Length 0.542410 mm

Use Automatic Inflation None

Inflation Option Smooth Transition

Transition Ratio 0.272

Growth Rate 1.2

Inflation Algorithm Pre

View Advanced Options No

Patch Conforming Options

Triangle Surface Mesher Program Controlled

Patch Independent Options

Number of CPUs for Parallel Part Meshing Program Controlled

Shape Checking Standard Mechanical

Element Midside Nodes Program Controlled

Straight Sided Elements No

Number of Retries Default (4)

Extra Retries For Assembly Yes

Rigid Body Behavior Dimensionally Reduced