Vol. 2, Issue 8, Part D (2016)

Abstract
The frictional heat generated in the disc brake when the rotating disc of an automobile is stopped by the action of the rubber pads affects the temperature profile and stress distribution all along the surface. The widely used disc brake material is Cast Iron, but due to its high specific density, it consumes a lot of fuel during the braking process. The present work is to develop the three dimensional finite element model of a disc brake in order to suggest a suitable alternative for the traditional Cast iron. Three different materials were considered for the present analysis namely, SS 420 Annealed, Titanium alloy and Aluminium alloy. The temperature profile, mechanical deformation and thermal stresses induced are studied for each of the materials. Furthermore, the output of the transient thermal analysis has been coupled with the static structural analysis to study their combined effects on the disc brake geometry. The result from the study reveals that the Aluminium alloy is the best among the three materials considered as it shows the least values of thermal and mechanical stresses induced as a result of the braking. The finite results are validated with the analytical results and found to be close correlation between them.