Design and Thermal Analysis of a Disc Brake in Car by using Finite Element Method

The disc brake is a device for slowing or stopping the rotation of a wheel. A brake disc (or rotor), usually made of cast iron or ceramic composites (including carbon, Kevlar and silica), is connected to the wheel and/or the axle. To stop the wheel, friction material in the form of brake pads (mounted on a device called a brake caliper) is forced mechanically, hydraulically, pneumatically or electromagnetically against both sides of the disc. Friction causes the disc and attached wheel to slow or stop. Brakes convert friction to heat, but if the brakes get too hot, they will cease to work because they cannot dissipate enough heat. This condition of failure is known as brake fade. Disc brakes are exposed to large thermal stresses during routine braking and extraordinary thermal stresses during hard braking. The aim of the project is to model a disc brake used in Honda Civic. Structural and Thermal is done on the disc brake. The materials used are Stainless Steel, Cast Iron and Aluminum Alloy. “Analysis is also done by changing the design of disc brake. Actual disc brake has no holes; design is changed by giving holes in the disc brake for more heat dissipation.� Modeling is done in Pro/Engineer and analysis is done in Ansys.