DESIGN OF DISC BRAKE ROTOR USING STATIC STRUCTURAL AND THERMAL PERFORMANCE ANALYSIS

Automotive braking systems are one of the most important safety systems of vehicles. They are mainly used to decelerate or stop a vehicle from an initial speed to required speed. Braking is a process of reducing the kinetic energy of wheel by the application of mechanical force, reduction of kinetic energy is accompanied by the generation of heat energy on the surface of the rotor disc. This excessive thermal loading can result in surface cracking and high wear of brake contact surfaces, these can also lead to overheating of brake fluid, seals and other components. The main task of reducing the surfaces temperature of brake rotor can be achieved by a few modifications in design by using vents in the rotor disc. A detailed study of structural and thermal analysis for the modified disc rotors such as solid, vented and vented with cross-drilled disc rotors is presented in this paper. The design carried out using CATIA V5 and the analysis is done by using ANSYS WORKBENCH 16.2 Software’s. Finally, the required profile and material which has less thermal stresses and structural deformation is observed by comparing the obtained results in the analysis