International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 04 | Apr 2025
p-ISSN: 2395-0072
www.irjet.net
Effect of Material Selection on the Structural and Thermal Performance of a Disc Brake 1B. Aditya Chandrashekar , 2Abhishek Pratap Singh Bhadauria 1Final Year BTech Student, Mechanical Engineering , K. J. Somaiya School of Engineering, Mumbai - 400077,
Maharashtra, India
2Assistant Professor, Mechanical Engineering Department , K. J. Somaiya School of Engineering, Mumbai - 400077,
Maharashtra, India ---------------------------------------------------------------------***--------------------------------------------------------------------alloys reduce weight but may exhibit lower thermal Abstract - Brakes play a crucial role in vehicle safety by resistance and conditions.
enabling controlled deceleration. Improper geometry and material selection can lead to disc rotor damage or failure, compromising braking efficiency and vehicle control. This research work centers on analyzing both structural and thermal behavior of braking parts (e.g., rotor, caliper) using various materials under differing conditions. Finite Element Analysis (FEA) is used to assess von Mises stress, overall deformation, and strain in structural tests, while thermal simulations evaluate temperature distribution and heat dissipation during abrupt braking.
braking
2. OBJECTIVES This research work focuses on assessing the structural and thermal performance of selected disc brake materials. The main objectives are listed below:
1. INTRODUCTION
1). To analyze the impact of different materials on the structural integrity of a disc brake rotor by evaluating von Mises stress, total deformation, and strain elongation under braking conditions.
Braking systems are essential for vehicle safety, ensuring controlled deceleration and stability.. Among braking components, the disc brake rotor significantly influences braking efficiency, thermal performance, and structural integrity. During braking, friction between the brake pad and rotor converts kinetic energy into heat, which, if not dissipated effectively, can cause thermal stress, material degradation, and reduced performance.
2). To examine the thermal characteristics of each material by measuring heat dissipation ability and temperature variation during emergency braking situations. 3). To compare and evaluate the suitability of different materials—Grey Cast Iron, Stainless Steel, Magnesium Alloy, 1060 Aluminum Alloy, and Vanadium Alloy—based on their mechanical and thermal properties.
Traditionally, Grey Cast Iron has long been favored for brake rotors owing to its wear resistance, thermal conductivity, and affordability.. However, the demand for lightweight, high-performance braking systems has led to the exploration of alternative materials such as Stainless Steel, Magnesium, and Aluminum alloys. While cast iron offers superior heat dissipation, its high weight increases un-sprung mass and affects fuel efficiency. Lightweight
Impact Factor value: 8.315
extreme
The findings provide a comparative analysis of different materials, highlighting trade-offs between structural integrity, thermal efficiency, and weight reduction. By identifying the optimal material for disc brake rotors, this study aims to contribute to advanced braking systems that enhance vehicle safety, performance, and energy efficiency in conventional and electric vehicles.
Key Words: Mechanical properties, CAD Modelling, Finite Element Analysis, Heat dissipation, Braking efficiency.
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This study employs Finite Element Analysis (FEA) to evaluate the effect of material selection on disc brake rotor performance. Structural and thermal simulations determine von Mises stress, deformation, strain, heat dissipation, and temperature distribution under sudden braking conditions. The modeling is conducted using SolidWorks 2023 and Solid Edge to ensure accurate representation of real-world scenarios.
The selected materials for this investigation include Grey Cast Iron, Stainless Steel, Magnesium Alloy, 1060 Aluminum Alloy, and Vanadium Alloy. The modeling and simulations are conducted using SolidWorks 2023 and Solid Edge. The results indicate that no single material excels in all conditions, with each material demonstrating strengths and limitations based on specific performance criteria. This study provides valuable insights into material selection strategies for optimizing disc brake efficiency and durability.
© 2025, IRJET
durability
4). To identify an optimal material that balances strength, thermal efficiency, durability, and weight reduction for improved braking performance and vehicle efficiency.
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