CONTENTS

CERTIFICATES
ACKNOWLEDGEMENT
LIST OF FIGURES
LIST OF TABLES
ABSTRACT
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CHAPTER NO TITLE PAGE NO

1. INTRODUCTION
1.1 Braking requirements 02
1.2 Classification of brakes 02
1.3 Disc brake 03
1.4 Applications of disc brake 06
1.5 Discs 06
1.6 Disc damage modes 09
2. LITERATURE SURVEY 15
3. INTRODUCTION TO PROE
3.1 Pro/engineer 20
3.2 Pro/ENGINEER Wildfire Benefit 20
3.3 Basic concept for the design 21
3.4 Modeling of brake disc 22
3.5 Circular ventilated hole brake disc 23
3.6 Elliptical ventilated hole brake disc 24
3.7 2D Drawing of circular ventilated hole brake disc 25
3.8 2D Drawing of elliptical ventilated hole brake disc 28
4. INTRODUCTION TO FEA
4.1 Introduction to FEA 28
4.2 General description of FEA 31
 4.3 Engineering Applications of FEM 32
4.4 Advantages of FEM 33
4.5 Disadvantages of FEM 34
5. INTRODUCTION TO ANSYS
5.1 Introduction to ANSYS 36
5.2 ANSYS types available 36
5.3 Thermal Analysis 37
5.4 Structural Analysis 39
5.5 Advantages of ANSYS 40
5.6 Steps Involved in Problem Solving 40
6. STRUCTURAL ANALYSIS OF DISC BRAKE
6.1 Overview of structural analysis 44
6.2 Types of structural analysis 44
6.3 Assumptions 45
6.4 Materials used 45
6.5 Benefits of Carbon cast steel over grey cast iron 46
6.6 Structural analysis of brake disc using grey cast iron 47
6.6.1 Structural analysis of circular ventilated hole brake disc 47
6.6.1.1 Imported model from Pro/e 47
6.6.1.2 Meshed model of disc brake 48
6.6.1.3 Load distribution model of disc brake 48
6.6.1.4 Deflection model of disc brake 49
6.6.1.5 Von-mises Stress 49
6.6.2 Structural analysis of Elliptical ventilated hole brake disc 50
6.6.2.1 Imported model from Pro/e 50
6.6.2.2 Meshed model of disc brake 51
6.6.2.3 Load distribution model of disc brake 51
6.6.2.4 Deflection model of disc brake 52
6.6.2.5 Von-mises Stress 52
 6.7 Structural analysis of Brake disc using Carbon cast steel 53
6.7.1 Structural analysis of circular ventilated hole brake disc 53
6.7.1.1 Imported model from Pro/e 53
6.7.1.2 Meshed model of disc brake 54
6.7.1.3 Load distribution model of disc brake 54
6.7.1.4 Deflection model of disc brake 55
6.7.1.5 Von-mises Stress 55
6.7.2 Structural analysis of Elliptical ventilated hole brake disc 56
6.7.2.1 Imported model from Pro/e 56
6.7.2.2 Meshed model of disc brake 57
6.7.2.3 Load distribution model of disc brake 57
6.7.2.4 Deflection model of disc brake 58
6.7.2.5 Von-mises Stress 58
7. THERMAL ANALYSIS OF DISC BRAKE 59
7.1 Overview of thermal analysis 60
7.2 Types of thermal analysis 60
7.3 Calculations for thermal analysis 61
7.4 thermal analysis of brake disc using grey cast iron 62
7.4.1 Thermal analysis of circular ventilated hole brake disc 62
7.4.1.1 Imported model from pro/e 62
7.4.1.2 Meshed model of disc brake 63
7.4.1.3 Load distribution on nodes and areas 64
7.4.1.4 Nodal Temperature distribution 64
7.4.1.5 Thermal Gradient distribution 65
7.4.1.6 Thermal flux distribution 65
7.4.2 Thermal analysis of Elliptical ventilated hole brake disc 66
7.4.2.1 Imported model from pro/e 66
7.4.2.2 Meshed model of disc brake 67
7.4.2.3 Load distribution on nodes and areas 67
7.4.2.4 Nodal Temperature distribution 68
7.4.2.5 Thermal Gradient distribution 69
 7.4.2.6 Thermal flux distribution 69
7.5.1 Thermal analysis of circular ventilated hole brake disc 70
7.5.1.1 Imported model from pro/e 70
7.5.1.2 Meshed model of disc brake 71
7.5.1.3 Load distribution on nodes and areas 71
7.5.1.4 Nodal Temperature distribution 72
7.5.1.5 Thermal Gradient distribution 73
7.5.1.6 Thermal flux distribution 73
7.5.2 Thermal analysis of Elliptical ventilated hole brake disc 74
7.5.2.1 Imported model from pro/e 74
7.5.2.2 Meshed model of disc brake 75
7.5.2.3 Load distribution on nodes and areas 75
7.5.2.4 Nodal Temperature distribution 76
7.5.2.5 Thermal Gradient distribution 77
7.5.2.6 Thermal flux distribution 77
8. RESULTS AND DISCUSSIONS 78
8.1 Result: Structural analysis 79
8.2 Result: Thermal analysis 80
9. CONCLUSION 81

BIBILOGRAPHY 93
 LIST OF FIGURES

FIGURE DESCRIPTION PAGE

NO. NO.

1.1 Components of a Disc Brake 05

1.2 Cross Drilled disc 06
1.3 Mountain Bike Disc Brake 07
1.4 Railroad bogie and Disc Brake 08
1.5 Reinforced Carbon Disc Brake 09
1.6 Brake Disc after Scarring 12
3.1 Stress concentration of circular hole 21
3.2 Stress concentration of elliptical hole 21
3.3 Pro/e model of circular vent hole brake disc of pulsar 22
3.4 Pro/e model of elliptical vent hole brake disc of pulsar 23
3.5 Pro/e model of circular vent hole brake disc 24
3.6 Pro/e model of elliptical vent hole brake disc 25
3.7 2D Drawing of circular vent hole brake disc 25
3.8 2D Drawing of elliptical vent hole brake disc 26
STRUCTURAL ANALYSIS OF GREY CAST IRON
STRUCTURAL ANALYSIS OF CIRCULAR VENT HOLE BRAKE DISC
6.1 Imported model from PRO/E 47
6.2 Meshed model 48
6.3 Load distribution 48
6.4 Displacement vector sum 49
6.5 Von Misses stress 49
STRUCTURAL ANALYSIS OF ELLIPTICAL VENT HOLE BRAKE DISC
6.6 Imported model from PROE 50
6.7 Meshed model 51
6.8 Load distribution 51
6.9 Displacement vector sum 52
6.10 Von Misses stress 52
STRUCTURAL ANALYSIS OF CARBON CAST STEEL
STRUCTURAL ANALYSIS OF CIRCULAR VENT HOLE BRAKE DISC
6.11 Imported model from PROE 53
6.12 Meshed model 54
6.13 Load distribution 54
6.14 Displacement vector sum 55
6.15 Von Misses stress 55
STRUCTURAL ANALYSIS OF ELLIPTICAL VENT HOLE BRAKE DISC
6.16 Imported model from PROE 56
6.17 Meshed model 57
6.18 Load distribution 57
6.19 Displacement vector sum 58
6.20 Von Misses stress 58
THERMAL ANALYSIS OF GREY CAST IRON
THERMAL ANALYSIS OF CIRCULAR VENT HOLE BRAKE DISC
7.1 Imported model from PROE 62
7.2 Meshed model 63
7.3 Load distribution on Nodes 63
7.4 Load distribution on Areas 64
7.5 Nodal temperature vector sum 64
7.6 Thermal gradient 65
7.7 Thermal Flux 65
THERMAL ANALYSIS OF ELLIPTICAL VENT HOLE BRAKE DISC
7.8 Imported model from PROE 66
7.9 Meshed model 67
7.10 Load distribution on Nodes 67
7.11 Load distribution on Areas 68
7.12 Nodal temperature vector sum 68
7.13 Thermal gradient 69
7.14 Thermal Flux 69
THERMAL ANALYSIS OF CARBON CAST STEEL
THERMAL ANALYSIS OF CIRCULAR VENT HOLE BRAKE DISC
7.15 Imported model from PROE 70
7.16 Meshed model 71
7.17 Load distribution on Nodes 71
7.18 Load distribution on Areas 72
7.19 Nodal temperature vector sum 72
7.20 Thermal gradient 73
7.21 Thermal Flux 73
THERMAL ANALYSIS OF ELLIPTICAL VENT HOLE BRAKE DISC
7.22 Imported model from PROE 74
7.23 Meshed model 75
7.24 Load distribution on Nodes 75
7.25 Load distribution on Areas 76
7.26 Nodal temperature vector sum 76
7.27 Thermal gradient 77
7.28 Thermal Flux 77
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TABLE.NO TITLE PAGE NO

6.1 Properties of materials 46

8.1 Result: Structural analysis 79
8.2 Result: Thermal analysis 80