Static Structural Analysis of a Four-Wheeler Disc Brake Using Different Materials on ANSYS

Braking system is an important component in any automobile. Whenever any automobile is in moving condition, we need some system to stop or decelerate the vehicle as & when rush appears or pits appear in the road. Braking system is employed for this vary role. Brakes of different types but for study I have considered disc brake rotor here. Vehicle to be selected is an Audi TT Mk3 Coupe. Conventionally Gray cast iron has been used for manufacturing the disc brake rotors but it is accompanied by a large weight which in turn increases the overall weight of vehicle. This increased weight increases the losses occurring in the vehicle during movement. It also reduces the brake efficiency. To counter these two problems, we must go for some other materials which can have lower weight & higher tensile strength, compressive strength etc. In this particular study six different materials have been tried & tested. These materials are Aluminium wrought, Aluminium alloy, aluminium alloy NL, carbon fibre, carbon epoxy UD, Carbon E-Glass epoxy UD. These materials have been analysed for equivalent (von-Mises) stress, total deformation, maximum principal stress & stress intensity. In the end a comparative analysis has been presented. In order to develop the model of disc brake rotor for conducting analytical solution in software, CATIA V5-6 R2017 software will be used to develop the model & ANSYS 19.2 will be used to analyse the model.