III.

Research Methodology
3.1 Material Properties

3.1.1 Carbon Ceramic Matrix Material

The goal of developing CMCs was to resolve the problems associated with traditional technical
ceramics such as alumina, silicon carbide, aluminum nitride, silicon nitride or zirconia. There are
various cracks caused by small defects or scratches. These materials easily break under the
mechanical or thermo- mechanical loads. On the other hand, the crack resistance is very low in
glass. There are number of particles(like as monocrystalline whiskers or platelets) were inserted
in the matrix to improve the crack resistance or fracture toughness.

3.1.2 Gray Cast Iron (GG20)

The composition of the grey cast iron disk brake rotor is 3.53 wt carbon percent, 2.04 wt Si
(Silicon) percent, 0.63 wt Mg (Manganese) percent, 0.1 wt S (Sulphur) percent, 0.06 wt P
(Phosphorus) percent, 0.29 wt chromium percent, 0.79 wt copper percent, 0.011 wt Ti
(Titanium) percent, 0.10 wt V (Vanadium) percent, and (Fe) Iron balance. The hard carbide
forming metals (Cr, Ti and V) thus total 0.401 wt percent, so that the ratio of 1.97 units of Cu
(Copper) to 1 unit of the hard carbide forming metal between the weight of Cu present and the
weight of aforesaid hard carbide forming metals.

Table 2. Properties of Disk Brake Materials

3.2 CAD/Geometry Modeling

The analysis geometry which is solid was designed with the Solidworks program according to
the dimensions specified (Fig 8. Disc brake geometry)

3.3 Meshing

A meshing strategy for a disc brake involves using a fine mesh in critical areas like fillets and
around holes, transitioning to a coarser mesh in less critical areas to save computational
resources.

Meshing stage is very important in finite element analysis in terms of numerical convergence.
The more the mesh quality is increased, the more accurate results are achieved.

Fig 9. Meshing

3.4 Boundary Conditions

As thermal analysis is done, the conditions to be taken into account are those that will influence
the thermal phenomena such as ambient temperature and that of the fluid. The objective of
this study is to perform thermal analysis of brake disk using the ANSYS Workbench software,
while selecting transient thermal analysis mode by injecting all the thermomechanical
properties of the materials used in the analysis, such as the disk and the brake pads. We
introduce the associated boundary conditions for each disk area.

Modeling requires discretization of the time axis. Unlike numerical control, the discretization of
the time axis does not have to be regular

Fig 10. Contacts Fig 11. Loads

Results

The total deformation and stress values of both materials are as follows. So, structural steel
was found to be more durable than stainless steel.

Fig 12. Structural Steel Equivalent Stress Fig 13. Stainless Steel Equivalent Stress
Fig 14. Structural Steel Total Deformation Fig 15. Stainless Steel Total Deformation

This study aimed to enhance the efficiency of disc brakes by optimizing their design through
computational methods. The main objectives were to improve the geometry of the disc and
choose the best material to achieve an optimal design.

3.5 Loading Conditions

3.5.1 Heat transfer coefficient
Heat transfer coefficient of the wall (h) is a physical quantity which is related to the
geometric design of the brake disk, the velocity of the air circulation, as well as other
parameters attached to the braking process. Indeed, when vehicle moves in motion, the
 heat exchange coefficient (h) in the company of air changes with the speed of the disk, it
depends on the form of brake medium. In transient case, this convective heat exchange
coefficient (h) is variable as function of time on each disk surface .This one, practically, has
nothing to do with the material, but it depends on the surface geometry as well as, the
conditions of law of the convective regime.
Figure 16. Values of heat transfer coefficient at the wall of the ventilated discs with materials
(a) FG25 AL, (b) FG20

3.5.2 Clamping Force

Clamping force control is one of the key technologies in the algorithm design and
implementation of electro-mechanical braking system, whose control effects directly affect the
vehicle braking performance and safety performance. In order to improve the clamping force
control performance of electro-mechanical braking (EMB) system, an EMB clamping force
control method based on Variable universe adaptive fuzzy PID (VUF-PID) controller is proposed,
and stretching factors are added to the fuzzy PID control. According to the operation of the
controlled object, the fuzzy theory domain can be adjusted in real time to keep the system in
the proper parameter value and improve the adaptive ability of the system.

3.5.3 Braking Torque

3.6 Coupled Thermo-Mechanical FEM Setup

A coupled thermo-mechanical Finite Element Method (FEM) setup for a disc brake involves
creating a 3D model and analyzing the interaction between thermal and mechanical fields
during braking. This is done by applying frictional heat generation and convection as thermal
loads, while simulating the mechanical stress from pad pressure, and then solving for the
coupled thermal and structural response to predict temperature, stress, deformation, and
thermal fatigue.

Key components of the setup include a transient analysis, a realistic friction model, and
appropriate boundary conditions based on experimental data.

Setup steps

1. Geometry and meshing:

- Create a 3D CAD model of the brake disc and pads. Ventilated discs have complex
geometries that require careful modeling.
- Discretize the geometry into a finite element mesh. The mesh density should be
sufficient to capture stress concentrations and thermal gradients.

2. Material properties:

- Define the material properties for the disc and pads, including thermal conductivity,
specific heat, and density.
- Consider using temperature-dependent material properties to improve accuracy at high
operating temperatures.

3. Boundary conditions:

- Thermal: Apply heat flux on the contact surfaces between the disc and pads, generated
from friction. Implement convection on the surfaces exposed to air.
- Mechanical: Apply a braking pressure or force on the pads to simulate the clamping
load. Constrain the model appropriately (e.g., fix the center hole).

3.8 Assumptions & Limitations

Disc brakes are an integral part of modern automotive braking systems, directly impacting the
safety and efficiency of vehicle operation. This article provides a detailed breakdown of the key
components of disc brakes, focusing on the brake disc and brake pads, as well as their
respective roles in achieving optimal braking performance.

Advantages

1. Stable Braking Performance: One of the key advantages of disc brakes is that their
performance is less affected by changes in friction coefficient. This results in more
consistent and reliable braking in various conditions, including wet environments.
 2. Efficient Heat Dissipation: The smaller friction surface of the brake pads, combined with
the ventilated design of the brake discs, ensures better heat dissipation. This makes disc
brakes particularly suitable for long-distance driving and high-speed braking, where heat
buildup can become an issue in drum brakes.

3. Easier Maintenance: Disc brakes are easier to maintain compared to drum brakes. The
simpler structure of disc brakes allows for quicker replacement of worn brake pads, and
the automatic adjustment of the gap between the brake disc and pads reduces the need
for frequent manual adjustments.

4. Smaller Size and Weight: For the same braking torque output, disc brakes are generally
smaller and lighter than drum brakes, making them a preferred choice for vehicles
where weight and size are important considerations.

5. Insensitive to Direction: Unlike drum brakes, disc brakes provide the same braking force
whether the vehicle is moving forward or backward. This makes them highly adaptable
to various driving conditions.

6. Reduced Pedal Travel: Disc brakes have a smaller gap between the brake disc and pads
(0.05 to 0.15 mm), which shortens the piston travel time in the brake caliper and allows
for a higher force transmission ratio in the braking system.

7. Improved Thermal Stability: The thermal expansion of the brake disc is minimal
compared to drum brakes, which prevents significant increases in brake pedal travel and
simplifies the design of automatic gap adjustment systems.

Disadvantages

1. Higher Manufacturing Costs: Due to the higher precision required in the manufacturing
process, disc brakes tend to be more expensive than drum brakes. The higher wear rate
of the friction material also adds to the long-term cost.

2. Higher Hydraulic Pressure Requirements: Disc brakes require a higher hydraulic

pressure to achieve the same braking force due to the smaller friction surface. This is
why disc brakes are typically used in vehicles equipped with servo assistance.