SASURIE ACADEMY OF ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

MINI PROJECT

FINAL REVIEW

Date:02.05.2019
 DESIGN AND ANALYSIS OF DISK PLATE
USING ANSYS

PROJECT MEMBERS: PROJECT GUIDE:

THARANIRAJ.M (713418402011) Mr. DINESHKUMAR.S.,M.E.,

ABSTRACT
This project is aimed to reduce the failure of the brake pads and disk
by increasing the dissipation of heat from the system. For this purpose, a disk
brake will be modelled using the real time model along with the brake pads.
Then based on the speed and friction between the disk and pad, the
heat generated will be calculated.
This setup will be analysed under structural and thermal conditions
using FEA packages to determine the heat transfer rate and structural
effects.
Later the disk will be redesigned accordingly based on the
recommendations to increase the heat transfer rate and the modified disk
will be analysed under same boundary conditions to determine the heat
transfer rate and structural effects.
PROJECT WORK FLOW
• Study of disk brakes
• Collecting the details regarding disk brake problems
• Collection of a remedies to avoid / control the failures
• Method selection for testing
• Designing a model of disk brake plate
• Material selection for the disk brake
• Modelling a disk brake system using real components
• Analysis
• Results and discussions
DISK BRAKES
• A disc brake is a wheel brake which slows rotation of the wheel by the
friction caused by pushing brake pads against a brake disc with a set of
calipers.
• The brake disc (or rotor in American English) is usually made of cast iron,
but may in some cases be made of composites such as reinforced carbon–
carbon or ceramic matrix composites. This 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
motion to heat, and if the brakes get too hot, they become less effective, a
phenomenon known as brake fade.
PROBLEMS IN DISK BRAKE
Discs are usually damaged in one of four ways:
• Scarring,
• Cracking
• Excessive rusting
PROBLEMS IN DISK BRAKE – CONTINUED….
Other problems in disk brake due to geometry issues are
PROBLEMS IN DISK BRAKE – CONTINUED….
• Out of the above problems, scaring and cracking occurs because of
the failure of disk pads.

• The pads get faded easily because of the more heat generated inside
the system during the application of the brakes.
REMEDIES
Problems like rusting and other geometrical issues can be controlled
using proper maintenance.
Following are the options available to reduce the scaring and cracking
problems in disk brake.
Providing heat ventilation pockets on the surface of disk
Providing pockets on the periphery of the disk
Circular grooves on the surface of disk
REMEDIES – CONTINUED….
MODELLING AND MATERIAL SELECTION
• Disk brake will be modelled using a real time component used in 4
wheeler.

• The dimensions will be taken first and then modelled using solidedge
software.

• Material selection will be done meanwhile during modelling the disk

brake.
MODELLING
TESTING METHODS
• The existing and proposed disk brakes should be tested for justifying
the results by comparison.

• For this purpose, we have used analytical methods with the help of
ANSYS software.

• Practical testing are more time consuming and more costly and so we
have planned for computerized analysis.

• We will be using static thermal analysis for this purpose.

ANALYSIS AND DISCUSSION
• ANSYS software will be used for analysis purpose.

• Static structural and static thermal analysis will be conducted to

determine the results based on structural and thermal loads.

• Based on the results for existing and proposed models, discussions

will be made by comparing the results and if any optimizations are in
need, it will be done.
Thank you