Design and Analysis of Brake Disc using Metal Matrix Composites

Braking is a process which converts the kinetic energy of the vehicle into mechanical energy which must be dissipated in the form of heat. The disc brake is a device for decelerating or stopping the rotation of a wheel. A brake disc (or rotor) usually made of cast iron or ceramic composites, is connected to the wheel and/or the axle. 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 to stop the wheel. The present research is basically deals with the modeling and analysis of solid disc brake using Pro-E and Ansys. Finite element (FE) models of the brake-disc are created using Pro-E and simulated using ANSYS which is based on the finite element method (FEM). In this research Coupled Analysis (Structural & Thermal analysis) is performed in order to find the strength of the disc brake. In structural analysis displacement, ultimate stress limit for the design is found and in thermal analysis heat flow rates, and heat fluxes to be calculated by varying the two different materials of the disc. Comparison can be done for displacement, stresses and nodal temperatures. Results will be compared for the two different material of the disc.