PHENIKAA UNIVERSITY FACULTY OF VEHICLE AND ENERGY ENGINEERINGGRADUATION PROJECT DESIGN REPORT On Design and Performance Analysis of the Braking System for a Student Prototype Car Course:
EXECUTIVE SUMMARY
Project summary
This project aims to develop a reliable braking system that meets performance standards by optimizing stopping distance and response time It also focuses on enhancing heat dissipation, reducing wear, and increasing braking effectiveness Through hands-on experience in design, material selection, and testing, students learn to translate theoretical concepts into real-world applications, ensuring practical understanding and innovation in braking technology.
Designing an effective braking system for a student prototype car is challenging due to its lightweight structure, limited budget, and use of non-standard components Current braking solutions often fall short for custom-built vehicles, resulting in problems like uneven braking, inadequate stopping performance, and component failures Developing a tailored braking system is essential to ensure safety, reliability, and optimal performance for student-built cars with unique design constraints.
A well-designed and thoroughly analyzed braking system is essential for ensuring the safety and reliability of a prototype car during testing and competition Developing a customized braking system that is efficient, lightweight, and tailored to specific performance requirements is crucial Proper performance, safety, and stability assessments under diverse driving conditions help optimize the braking system, enhancing overall vehicle safety and operational stability.
Constraints Weight Constraint: The brake disc must weigh no more than 5 kg to ensure minimal impact on vehicle efficiency.
Thermal Constraint: The brake disc must operate effectively at high temperatures, withstanding up to 500°C without significant performance degradation.
Regulatory Constraint: The design must comply with automotive safety standards and material regulations for road vehicles.
Manufacturing Constraint: The brake disc should be manufacturable using conventional machining and casting techniques to maintain production feasibility.
Performance Constraint: The disc must achieve an optimal balance of strength, durability, and heat dissipation.
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Total brake disc weight kg ≤ 8
Brake disc type - Drilled, slotted, vented, and combined
The design process consists of the following outcomes:
A lightweight brake disc that reduces weight by at least 10% compared to conventional designs.
Improved thermal efficiency, allowing the brake disc to handle temperatures up to 500°C without performance loss.
Enhanced structural integrity, reducing deformation and stress under extreme braking conditions.
A cost-effective design that remains within a suitable budget while maintaining high performance.
Compliance with automotive safety standards and material regulations for road vehicles.
Design Process
The design process for a braking system involves several structured stages to ensure effectiveness and reliability Key steps include identifying specific requirements, selecting appropriate materials, planning project milestones, and utilizing advanced analysis and testing methodologies This systematic approach guarantees the development of a high-quality braking system that meets safety and performance standards.
- Step of the design process:
1 Identify Requirements: Gather design requirements based on automotive safety standards and performance needs.
2 Concept Development: Evaluate various brake disc types (e.g., drilled, slotted, vented) to determine the most suitable configuration for performance and durability.
3 Material Selection: Choose high-performance materials like AISI 5140 (EN18) steel for enhanced mechanical strength and thermal resistance.
4 CAD Design: Utilize CATIA V5 to create detailed 3D models of the brake disc, optimizing dimensions and geometry for structural efficiency.
5 FEA Simulation: Perform structural and thermal analysis using ANSYS to assess stress distribution, heat dissipation, and deformation under real-world braking conditions.
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6 Prototyping: Produce a physical prototype through precision machining and casting processes to validate the CAD model before moving to mass production.
7 Testing & Validation: Conduct real-world testing including
8 Optimization: Analyze test results to identify improvements, refine the design, and enhance overall brake disc performance and reliability.
To ensure a high-performance and durable braking system, the following materials and equipment are used:
Materials: o Brake Disc: AISI 5140 (EN18) steel for high strength, wear resistance, and thermal stability. o Brake Pad: Carbon-ceramic composite for superior heat resistance and friction performance.
Software & Tools: o CATIA V5 for 3D modeling. o ANSYS for FEA simulations (structural and thermal analysis). o MATLAB Simulink for system-level performance evaluation.
A comprehensive 12-week project schedule has been designed to effectively track key milestones including material selection, CAD modeling, prototyping, testing, and optimization This structured timeline ensures each phase is completed on time, utilizing tools like Gantt charts or tables for clear progress management Proper scheduling is essential for maintaining project efficiency and meeting deadlines in product development processes.
Table 2 A structured 14-week project schedule
Our project begins with problem identification, where we thoroughly define and document the FSAE braking requirements within one week to ensure precise system specifications Next, we focus on material identification by selecting and testing potential materials based on performance and cost-effectiveness, which also takes one week Finally, we develop detailed CAD models of the brake system over a two-week period, enabling accurate design and analysis to meet the project’s objectives efficiently.
Simulation Perform FEA and CFD simulations to evaluate design robustness 8 Weeks
Improvement Optimize the design based on test feedback 2 Week
Used CAD software for precise modeling and FEA (Finite Element Analysis) for stress and load analysis.
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EmployedCFD (Computational Fluid Dynamics) to study heat dissipation.
Validated through physical tests such as braking under load, endurance trials, and thermal resistance evaluation.
Results
The optimized drilled and vented brake disc design significantly improved braking efficiency, thermal performance, and durability while maintaining cost-effectiveness.
Weight Reduction: Achieved a 10% reduction, enhancing vehicle efficiency.
Heat Dissipation: Improved by 20%, reducing overheating risks.
Maximum Temperature: Maintained below 500°C under extreme braking.
Stress & Deformation: Ensured structural stability with minimal deformation (3.31 × 10⁻⁵m) and controlled stress (2.37 × 10⁸Pa).
Recommendations
Based on thefindings of this studyresults, the following recommendations are proposed to further enhance the performance, durability, and cost-effectiveness of the brake disc design:
Material Optimization: Explore advanced materials such as carbon-ceramic composites to further improve heat resistance and reduce weight.
Manufacturing Enhancements: Implement precision casting and CNC machining to enhance production efficiency and quality control.
Surface Coatings: Apply thermal barrier coatings to further reduce heat build-up and extend brake disc lifespan.
Design Refinements: Conduct additional computational and experimental testing on different slot and hole patterns to maximize cooling efficiency.
Cost Reduction Strategies: Optimize the manufacturing process and material procurement to lower production costs while maintaining performance.
Real-World Testing: Perform extensive road and track tests under various driving conditions to validate long-term durability and performance.
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PROBLEM DEFINITION AND BACKGROUND
Problem statement and definitions
In the automotive industry, safety and performance are paramount, with the braking system being a critical component ensuring reliable and efficient stopping power across diverse conditions The Infiniti Prototype 9, a one-of-a-kind electric concept inspired by 1940s Grand Prix race cars, seamlessly blends classic aesthetics with cutting-edge electric drivetrain technology Although primarily designed as a showcase of innovative design and engineering, the Prototype 9 presents real-world challenges in developing and integrating a high-performance braking system.
As a concept car, the Prototype 9 must balance:
Vintage design constraints, such as exposed wheels and narrow track width,
Modern safety and performance expectations, especially regarding braking response,
And a lightweight body (only 890 kg) that changes conventional brake sizing and heat management strategies.
Ensuring the braking system aligns with the vintage design while delivering reliable performance under modern testing conditions is a key challenge Limited documentation on its thermal behavior, brake balance, and fade resistance under prolonged stress raises concerns about its durability and safety These critical factors are especially important even in concept vehicles designed primarily for limited demonstration purposes.
Background and Technical Review
The Infiniti Prototype 9 is a concept electric vehicle that combines classic 1940s Grand Prix racing aesthetics with contemporary EV technology, serving as a showcase of innovative design and engineering Its fully functional mechanical components, including the braking system, are designed to meet dynamic driving and safety requirements With a lightweight structure of approximately 890 kg and an advanced electric drivetrain, the vehicle’s brake system benefits from regenerative braking, which recovers energy and reduces mechanical brake wear, setting it apart from conventional internal combustion engine vehicles.
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The vintage, open-wheel design of the vehicle presents unique challenges for brake packaging and airflow management As a result, the thermal performance of the braking components—particularly the front ventilated discs—is crucial for ensuring optimal braking efficiency and safety Proper heat dissipation is essential to prevent overheating and maintain the brakes' effectiveness under demanding conditions.
The Prototype 9 was never designed for mass production or high-speed racing; however, its braking system needed to deliver stable, predictable, and responsive performance This ensures the vehicle's safety, reliability, and controllability during testing, demonstrations, and dynamic driving events, highlighting the importance of high-quality brakes for various driving scenarios.
2.2.2 Technical Review of the Current Infiniti Prototype 9 Braking System
The Prototype 9 uses a four-wheel disc brake system, which reflects a modern approach to braking despite the vintage exterior.
The front of the vehicle features ventilated disc brakes, which are crucial for effective braking performance by efficiently dissipating heat generated during deceleration This design is particularly important because the front axle endures a higher braking load due to weight transfer during braking, ensuring safety and reliability.
The Infiniti Prototype 9 is equipped with solid disc brakes at the rear, offering a lightweight and straightforward design ideal for handling the lower braking forces on the rear axle of a rear-wheel-drive, lightweight vehicle These rear brakes are designed for simplicity and efficiency, contributing to the vehicle's overall performance Key technical specifications of the braking system highlight its capacity to deliver reliable stopping power while maintaining a reduced weight profile, enhancing the car's handling and driving dynamics.
Table 3 Infiniti prototype 9 brake disc parameters
Disc Diameter Front: 252 mm, Rear: 252 mm
Disc Thickness Front: 25 mm, Rear: 10 mm
Braking System Hydraulic with ABS, EBD, and BA
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Ventilated front brake discs are engineered to improve heat dissipation compared to solid discs, minimizing brake fade during intense braking Despite this, challenges such as heat accumulation, weight reduction, and material efficiency still need to be addressed A redesigned brake disc must be benchmarked against existing specifications to ensure enhanced heat management, structural durability, and optimal braking performance.
2.2.3 Scientific and engineeringBackground research on brake disc optimization
Numerous studies have investigated methods to enhance automotive brake disc performance by reducing weight, improving material properties, and optimizing thermal behavior These insights serve as a practical foundation for our capstone project, which focuses on redesigning the brake disc for the Infiniti Prototype 9 to achieve greater durability and efficiency.
Generative design techniques that significantly reduce disc weight while maintaining strength [1].
Use of hybrid aluminum composites to improve thermal performance and wear resistance under real-world conditions [2].
The critical role of material selection in balancing performance, fuel efficiency, and cost [3].
Structural and thermal simulation approaches that identify stress points and guide design improvements [4].
This project builds on those insights to develop a brake disc optimized for lightweight structure, enhanced heat dissipation, and long-term reliability using advanced materials and simulation tools.
2.2.4 Technical Challenges and Design Considerations
Designing an optimized brake disc for the Infiniti Prototype 9 requires addressing technical, economic, and regulatory challenges to ensure superior performance, durability, and industry compliance The new brake disc must enhance thermal efficiency, braking force, and material sustainability, while remaining cost-effective and manufacturable through standard automotive production techniques.
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Table 4 below outlines the key technical challenges and design considerations, explaining their relevance to the project:
Table 4 Key technical challenges and design considerations
Constraint Description Relation to the Project
Technical The technology required to implement the design Ensuring compatibility with the
Infiniti Prototype 9 braking system while improving heat dissipation and wear resistance.
Economic Budget limitations and cost efficiency Keeping the material and manufacturing costs low while maintaining performance.
Manufacturability Feasibility of production and assembly Ensuring the brake disc design is
CNC machinable and castable for mass production.
Functionality Performance requirements and operational constraints.
Achieving effective braking force with a minimum deceleration of 1G while ensuring thermal stability.
Safety Ensuring user and operational safety Designing components to withstand high temperatures (up to 500°C) and extreme braking forces.
Standards Compliance with industry regulations and testing Meeting SAE J2522 brake performance testing standards for reliability and efficiency.
Sustainability Long-term environmental impact and recyclability Using recyclable materials such as high-performance steel alloys to enhance sustainability.
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DESIGN SOLUTIONS
Analysis and Synthesis
3.1.1 Determine and calculate braking force, required torque and brake disc parameters 3.1.1.1 Theoretical basis a) Determine and calculate braking force, required torque
Brake force and torque are essential parameters for determining the optimal size and geometry of a brake disc, ensuring effective and even braking performance Precise calculation of these values guides the selection of appropriate materials — such as those with high thermal resistance and wear durability — and influences structural design to withstand intense thermal and mechanical loads Accurate brake force and torque assessments are crucial for designing brake discs that operate safely, reliably, and efficiently in real-world conditions These calculations can be approximately performed using specific formulas to ensure optimal brake system performance.
The braking force of each wheel in the front and rear axles:
Braking torque of each wheel on the front and rear axles:
𝑀 𝑝1 = 𝑃 𝑝1 𝑟 𝑏𝑥 ; 𝑀 𝑝2 = 𝑃 𝑝2 𝑟 𝑏𝑥 b) Calculation of the basic parameters of the brake mechanism
After having the parameters of the force and torque generated on the wheel during braking, it is possible to preliminarily determine the basic parameters of the brake disc, including:
inner and outer radii of brake discs
Average radius of brake discs
Brake torque generated by the brake mechanism and the required pressure
Bearing angle of friction plate
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For design calculation specifications, refer to the table below with the main specifications [5].
Table 5 Basic parameters of the model car
STT Name Ampersand Value Unit
- From the parameter table from the registry, we have the following main parameters:
G – The total weight of the car, the point located at the center of gravity coordinates of the vehicle, the direction is as shown in the drawing.
𝐺 1 - The total weight of the car applied to the bridge before it is fully loaded
𝐺 2 - The total weight of the car applied to the bridge after full load
𝑍 1 - Normal jet from the road surface to the front wheels of the vehicle
𝑍 2 - Normal jet from the road surface to the rear wheels of the vehicle
𝐿 0 – The wheelbase of the vehicle
ℎ𝑔- The height of the vehicle's center of gravity
a - The distance from the front axle to the center of gravity of the vehicle
b - The distance from the rear axle to the center of gravity of the vehicle
- Determination of the length of the distance from the center of gravity to the front and rear bridges:
Determining the distance from the center of gravity to the front and rear axles is essential for optimal engine positioning and vehicle control Accurate measurement of these distances (a) and (b) plays a crucial role in enhancing vehicle stability, handling, and performance Understanding the distribution of weight in relation to the axles helps improve safety and driving dynamics, making it a vital aspect of automotive design and engineering.
At Phenikaa University, internal documents include detailed specifications from the car manufacturer, such as weight distribution to the front (G1) and rear (G2) axles, total vehicle weight (Throttle), and wheelbase (Lo) These parameters enable precise calculation of the distance from the center of gravity to each axle, using formulas based on the distribution of weight between the front and rear wheels Understanding these specifications is essential for assessing vehicle stability and performance.
We have: The weight distribution on the front axle and the rear crane after no load are 550 and 450, respectively There is a wheelbase again 𝐿 0 = 2700 => a = 1215 (mm), b = 1485 mm
The total weight of the car applied to the front axle and after full load is, respectively: G1 b1,5 (kg), G2 = 508,5 (kg)
- Determination of the height of the center of gravity:
The center of gravity coordinates based on the vehicle's height (hg) lack a specific calculation formula and must be determined through experimental methods, including diagrams and identification techniques In practical applications, such as designing brake systems where the height of the center of gravity is required, reference data is commonly used to ensure accurate and reliable results.
For small trucks (500kg-1500kg), hg = 0.9m -1.1m
For medium trucks (3500kg-4500kg), hg = 1.1m-1.3m
- Determine the working radius of the wheel𝑟 𝑏𝑥
The working radius of a wheel, defined as the distance from its center to the point of contact with the pavement or work surface, is a crucial parameter for calculating the forces and torque acting on the wheel Accurate determination of this radius is essential in engineering applications involving wheel performance and load analysis This parameter is typically calculated using tire specifications and performance data, ensuring precise assessments for optimal wheel design and functionality.
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According to the reference vehicle parameters, we have tire designation: 205/60R16 We have:
Number 205 is the width of the tire: B 5
The number 60 represents the ratio between the height and width of the tire, i.e.:
Radial, an abbreviation for the circular tire structure, highlights the design of tires that feature a radial ply construction for enhanced performance The number 18 indicates the diameter of the wheel rim in inches, with 𝑑 = 18 inches, providing a clear measurement for wheel size Specifically, the Infiniti Prototype 9 car wheels are designed with an 18-inch diameter, defining their size and compatibility Understanding these measurements is essential for selecting appropriate tires and ensuring optimal vehicle performance.
2 ⋅ 25,4 ≈ 326,2( mm) With as a factor, the height deformation of the tire Choose = 0,935
The working radius of the wheel is calculated according to the formula:
- Determine the braking force at each wheel
The braking force at a car's wheels can be estimated by calculating the load applied to each wheel and understanding how the load redistributes to the front axle during braking This involves using specific formulas that account for vehicle weight, deceleration rate, and load transfer effects Properly analyzing these factors is essential for assessing braking performance and ensuring safety.
In which: - 𝐽 𝑝𝑚𝑎𝑥 : The largest braking acceleration of the car Choose 𝐽 𝑚/𝑠 2
At that time, we can calculate the braking force generated at the wheel by the formula:
- Braking force of each wheel on the front axle:
- Braking force of each wheel on the rear axle:
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Once the braking force at the wheel has been determined, we can determine the torque generated at that wheel based on the working radius of the wheel:
Braking torque of each wheel in the front axle:
𝑀 𝑝1 = 𝑃 𝑝1 𝑟 𝑏𝑥 = 2079.0,305 = 634,09 (𝑁.𝑚) Brake torque of each wheel on the rear axle:
𝑀 𝑝1 - The braking torque of each wheel on the front axle.
𝑃 𝑝1 - The braking force of each wheel on the front axle.
𝑀 𝑝2 - The braking torque of each wheel on the rear axle.
𝑃 𝑝2 - The braking force of each wheel on the rear axle. b) Calculation of the basic parameters of the brake mechanism
- The outer and inner radii of the brake disc
The inner and outer radius of the brake disc refer to the distances from the axis of rotation to the inner and outer edges of the disc, respectively These measurements are essential for calculating braking torque, as they directly influence the torque required to slow down or stop a vehicle In disc brake systems, the radius values are used in the torque calculation formula to determine the appropriate power needed for effective braking performance.
- The radius outside the brake disc (𝑅 2 ) is determined by the following formula
Figure 1 Main design parameters of brake discs
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Wheel rim thickness, for the car takes𝛿 𝑣 = 6( mm),
Clearance distance between wheel rim and brake disc
We can change the number:𝑅 2 = 𝑅 𝑣 − 𝛿 𝑣 − 𝛥 𝑣−𝑑 = 203,2 − 6 − 48 = 150,2[mm] Select the radius of the brake disc as:𝑅 2 = 150 mm = 0,15 𝑚.
R1is the inner radius of the disk, they can be selected empirically by R1=0,52÷0,73.
- Average radius of brake discs
The average radius is a crucial factor in brake disc calculations, ensuring that braking force is evenly distributed across the entire braking surface for optimal performance To determine this measurement, a specific formula can be used to approximate the average radius of brake discs accurately Incorporating this calculation helps improve braking efficiency and safety by maintaining balanced force distribution.
The braking torque produced by a disc brake mechanism is similar to that of a mechanical friction clutch, with friction torque generated by two brake shoes These brake shoes exert equal frictional forces (Mg1 = Mg2) thanks to symmetrical piston actuation, which applies uniform oil pressure on either side of the disc This balanced pressure ensures consistent braking performance and optimal control.
Disc brakes feature a symmetrical compression mechanism across the plane of the brake disc, ensuring balanced performance The friction torque generated by the disc is uniform because the brake pads exert equal force on both sides This symmetry is achieved through two pistons applying equal oil pressure, resulting in consistent and reliable braking power Proper design of the brake system enhances safety and efficiency by maintaining even force distribution on the disc.
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When the pressures P1 and P2 are assumed to be equal and set at the P pressure of the piston, the total brake torque produced by the two brake pads on the brake disc can be accurately calculated This uniform pressure assumption simplifies the analysis of brake performance and efficiency, ensuring consistent and effective braking force Understanding how pressure distribution impacts brake torque is essential for optimizing brake system design and ensuring reliable vehicle safety.
R2: is the outer radius of the disc
R1: is the inner radius of the disc
𝜇: is the sliding friction coefficient between the brake pads and the brake discs. According to empirical data𝜇=0.3÷0.33 Select𝜇=0.3
The formula for calculating the required pressures P for the disc brake mechanism is determined as follows:
𝑅 2 3 − 𝑅 1 3 ) Changing the data, we have pressure on the front/rear brake mechanism Front brake mechanism with data:
Replace the number with us:
0.15 3 −0.082 3 = 8856,86(𝑁) Rear brake mechanism with data:
Replace the number with us:
The width of the brake pads directly influences the effective contact area between the pads and the brake disc Increasing pad width generally enlarges the working area, which helps
Using internal copies at Phenikaa University helps distribute pressure more evenly, reducing localized stress on the brake system This leads to a decrease in wear rate per braking event, thereby enhancing the durability and lifespan of the friction material Moreover, increasing the contact area between brake pads and discs improves heat dissipation, which minimizes thermal stress and maintains optimal braking performance.
Excessive brake pad width can cause non-uniform pressure distribution across the contact surface, leading to uneven pad wear and reduced braking performance Optimizing brake pad width is crucial to ensure a balance between wear characteristics, heat dissipation, and pressure uniformity Properly designed brake pads enhance braking consistency, improve overall efficiency, and ensure reliable and safe vehicle operation.
With the disc brake type, the width of the brake pads can be determined approximately according to the formula:
- Embrace angle of friction plate:
To determine the angle at which the friction plate engages, we can calculate it using the force applied to the brake disc and the average working pressure generated between the brake pads and the disc This calculation allows for precise assessment of brake performance and ensures optimal friction plate alignment Understanding this relationship is essential for maintaining effective braking efficiency and safety.
Generating multiple solutions
For the comparison analysis, this project proposed for disc design as shown in Figure 5 below:
Vented disc brake rotor (Solution 2)
Slotted disc brake rotor (Solution 3)
Drilled and vented disc brake rotor (Solution 4)
Mass: 3,17 kg Mass: 2,6 kg Mass: 2,49 kg Mass: 2,5 kg a b c d
Figure 6 Table of new brake disc designs
Drilled rotors feature holes drilled through their thickness, designed to enhance heat dissipation during braking These drilled holes create a pathway for faster heat transfer, allowing the rotor to cool more quickly and reduce the risk of overheating Additionally, the bores enable gases that build up during braking to escape efficiently, improving braking performance and reducing brake fade.
Drilled disc brake rotors help prevent trapping between the disc surface and brake pad material, with holes that significantly reduce brake fade and enhance braking performance However, while these drilled holes improve braking efficiency, they can also weaken the rotor, making it more susceptible to fatigue and crack development over repeated braking cycles Consequently, the durability of drilled rotors is reduced, and they may exhibit structural damage, as shown in Figure 3.
- Slotted/ grooved disc brake rotors:
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Slotted (or grooved) disc brake rotors feature carved slots that help evacuate gases, heat, and water from the braking surface, enhancing braking performance Commonly used in high-performance vehicles, these rotors effectively remove brake pad dust and prevent pad glazing, ensuring consistent braking efficiency While slotted rotors offer improved heat dissipation and cleaner pads, they tend to produce noise during braking due to pad scrubbing and may cause faster brake pad wear Table 9c provides an overview of typical slotted/grooved disc brake rotors, highlighting their characteristics and applications.
Vented brake discs feature ventilation grooves or internal slots that enhance heat dissipation, preventing overheating during braking These design elements facilitate air circulation through the disc, maintaining optimal temperature and improving overall braking performance By efficiently managing heat, vented brake discs extend the lifespan of the braking system, making them ideal for demanding driving conditions and continuous braking situations.
To come up with new designs and the simulation, we used CATIA V5 software to model the designs based on the dimensions of the base brake disc.
Table 13 Properties of new brake disc design options
Dısc Solutıon Mesh sıze Thıckness Mass
Drilled disc brake rotor Solution 1 2 mm 12 mm 3,17
Vented disc brake rotor Solution 2 2 mm 14 mm 2,6
Slotted disc brake rotors Solution 3 2 mm 14 mm 2,4
Drilled and vented disc brake rotor Solution 4 2 mm 14 mm 2,5
Drilled and vented disc brake rotor
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Figure 7 Mechanical mesh details of 4 solutions
Meshing is a critical step in finite element analysis (FEA) as it directly impacts the accuracy and convergence of the simulation results The choice between fine and coarse meshing significantly influences the final outcomes, making it essential to select the appropriate mesh density In this project, fine meshing was achieved using triangular surface meshes for disks and quadrilaterals for pads to ensure detailed analysis For the original brake disc simulator simulation, a 4 mm mesh size was employed to balance computational efficiency and result precision.
Design analysis
- Disc material: SiCn/6061 Al composite
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Figure 8 Total deformation of results of 4 solutions
The disc is securely fixed in the shaft mounting position, with the outer edges of both pads anchored Mattress pressure of 0.458 MPa is applied to both cushion surfaces to simulate operational conditions A moment of 634.09 N·m is exerted at the center of the disc, with these parameters applicable across all four disc brake models The analysis evaluates the disc for overall deformation and equivalent stress to ensure structural integrity under specified loads.
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Figure 9 Equivalent Stress results of 4 solutions
Maximum allowable stress:3,01e+7 Pa Maximum allowable stress:3,2e+7 Pa
Maximum allowable stress: 3,15e+7 Pa Maximum allowable stress:3,13e+7 Pa
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Figure 10 Heat distribution results of 4 solution
For the thermal analysis of disc 1, the initial temperature condition was taken into account, along with the effect of radiation The results were plotted as a distribution of temperature.
After analyzing four different solutions, our results demonstrated a significant reduction in temperature, with the improved brake disc providing superior cooling efficiency compared to the original design However, structural modifications led to increased strain and deformation over four testing rounds, highlighting potential trade-offs in the brake disc's durability and performance.
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Selected/Optimal solutions
In brake disc design, the most critical factor is temperature, as efficient heat dissipation ensures consistent braking performance under high-temperature conditions Deformation must also be carefully considered to prevent excessive distortion that could impair braking effectiveness Stress analysis is essential to assess the disc's load-bearing capacity and durability across various operating scenarios Finally, weight optimization balances performance with material efficiency, ensuring the system remains lightweight without sacrificing safety or functionality A well-structured design matrix prioritizes these factors—temperature, deformation, stress, and mass—by analyzing each criterion to achieve optimal brake disc performance and longevity.
- Step 1: Identify Factors and Evaluation Criteria
Temperature: Heat resistance, heat dissipation, maximum operating temperature.
Deformation: Stiffness, deformation resistance, and shape change under pressure.
Stress: Load-bearing capacity, fatigue strength, maximum stress tolerance.
Mass: Specific weight, overall weight of the brake disc.
Assign weights to each factor based on the given priority order:
- Step 3: Establish the Design Matrix
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Create a matrix with factors and evaluation criteria, then fill in the corresponding weights.
Table 14 Brake disc design priority matrix
Temperature 4 Heat resistance, heat dissipation
Stress 2 Load-bearing capacity, fatigue strength
Mass 1 Specific weight, overall weight
The temperature distribution after braking indicates the highest temperatures occur at the contact area between the brake pad and rotor, as shown in Table 19 and the contour plot This area experiences increased frictional heat flow during braking, leading to elevated temperatures The braking process converts the vehicle's kinetic energy into heat through the rubbing action of the brake pads, which is then absorbed by the disc For a conventional vented rotor, the maximum temperature recorded is 315.65°C, highlighting the heat accumulation in this critical contact zone.
The maximum temperature in brake systems occurs in the ring region where the brake pad contacts the rotor, with the highest recorded temperature being 418.99 °C for drilled disc brake rotors In comparison, grooved disc brake rotors reach a peak of 306.95 °C, while drilled and vented rotors have a maximum temperature of 306.9 °C, indicating better heat dissipation The drilled and vented disc brake rotor design demonstrates superior thermal management by maintaining the lowest temperature after braking, highlighting its effectiveness in dissipating heat Variations in temperature distribution influence thermal stresses, strains, and deformation, which are critical considerations in the static structural analysis of brake components.
The stress and strain distributions in the brake rotors closely correspond to the temperature distributions, with drilled and vented disc brake rotors exhibiting the lowest stress and strain values In contrast, conventional brake rotors experience the highest stress and strain levels, as detailed in Tables 18 and [appropriate table number], highlighting the impact of rotor design on thermal and mechanical performance.
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19 We observe that the highest thermally induced stress and strain are located on the disc with the highest temperature distribution This can also be observed across the four designs For the drilled disc brake rotor design, the stress and strain distributions are the lowest; for the three vented designs, the slotted disc brake rotor records the highest stress, and the drilled and vented disc brake rotor records the lowest values In this respect, the first design has the closest stress and strain distribution values to the base disc; however, the three vented design options have the potential to significantly reduce temperatures while reducing Disc weight while still meeting the material strength requirements see Table 14 for more details on these values From there, we will set up the design matrix.
Table 15 Summary table of analysis results of 4 solutions
For ease of calculation, we will standardize the score value from 1 to 4 for each criterion.
Drilled and vented disc brake rotor
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Factor Weight Drilled disc brake rotor
Drilled and vented disc brake rotor
Based on the design matrix and the total scores of various brake disc options, the "Drilled and vented disc brake rotor" stands out as the optimal choice It achieved the highest total score of 31, indicating its superior performance and suitability This evaluation highlights the effectiveness of the drilled and vented design in enhancing braking efficiency and reliability.
This option scores the highest across all four critical factors: temperature, deformation, stress, and mass Specifically:
Temperature: Scores 4 indicate the best heat resistance, which helps minimize performance degradation during high-temperature braking.
Mass: Scores 3, being the lightest among the options, contributing to reduced unnecessary weight, improving overall vehicle performance, and fuel efficiency.
Deformation: Scores 2 suggest an acceptable level of deformation, ensuring the brake disc does not warp excessively during operation.
Stress: Scores 1, ensuring good load-bearing capacity and stress distribution, enhancing the brake disc's durability and lifespan.
The "Drilled and vented disc brake rotor" scores the highest with 31 points, making it the top choice compared to the "Drilled disc brake rotor" (19 points), the "Vented disc brake rotor" (21 points), and the "Slotted disc brake rotors" (29 points) Its combination of drilling and venting improves heat dissipation, reduces weight, and maintains high durability, making it the ideal solution for enhancing braking system performance.
EVALUATION AND RECOMMENDATION
Risk analysis
Scale Type Level Rating Description
Very Low 1 • Extremely unlikely to occur; rare incidents that almost never happen.
Low 2 • Possible under unusual conditions; unlikely but not impossible.
Moderate 3 • Fair chance of occurrence; may happen occasionally under normal operating conditions.
High 4 • Likely to occur; may happen frequently if not well-controlled.
Very High 5 • Almost certain to occur without preventive actions.
Very Low 1 • Insignificant effect on performance; does not interfere with system operation.
Low 2 • Minor effect; easily manageable without disrupting operations.
Moderate 3 • Noticeable impact requiring adjustments; performance reduced but system still operational.
High 4 • Significant impact requiring major changes or temporary shutdown.
Very High 5 • Critical failure; system breakdown or redesign needed.
The scenario method is essential for risk assessment and predicting potential opportunities in brake system design It helps identify possible hazards early in the development process, allowing for improvements that enhance safety and reliability By utilizing this approach, engineers can optimize brake systems before real-world implementation, ensuring better performance and reduced risk of failure.
Identifying Potential Hazards: The method begins by analyzing hazardous situations that could compromise safety, such as emergency braking, braking on slippery or inclined surfaces, or during high-speed maneuvers.
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Each scenario is thoroughly detailed, outlining initial conditions, the expected performance of the braking system, and the desired results For instance, it may describe a vehicle traveling at high speed on a wet road requiring urgent braking to prevent a collision This comprehensive approach ensures clarity in testing scenarios and safety protocols, vital for optimizing vehicle safety systems Clear scenario descriptions enhance understanding of vehicle behavior in critical situations, aligning with safety standards and improving user trust.
Conducting a consequence assessment is essential to evaluate the potential outcomes of a braking system failure, including the risk of vehicle accidents, injuries, fatalities, or material damage This step helps identify the severity of possible failures and informs safety measures, ensuring effective risk management and mitigation strategies.
Effective risk mitigation measures include implementing technical enhancements such as upgrading braking systems, improving driver training programs to increase safety awareness, and upgrading infrastructure with better road surface treatments, all based on thorough scenario analysis to ensure targeted prevention.
Validation and approval are crucial steps in the risk management process, requiring review and validation of all proposed scenarios and risk control strategies by qualified experts Their approval ensures that safety and compliance are maintained before moving on to the design implementation phase.
Assessing risk in brake system design is crucial for ensuring safety, performance, and durability A structured approach involves identifying potential hazards through systematic evaluation, which helps in mitigating risks effectively Proper risk assessment enables engineers to enhance brake system reliability and compliance with safety standards, ultimately leading to safer vehicle operation and longer-lasting brake components.
These include situations that may result in reduced brake performance or failure, such as excessive brake wear, overheating, or delayed response during emergency braking.
Risk factors are the root causes of hazardous events They may stem from improper design calculations, selection of inappropriate materials, manufacturing defects, or lack of quality control during assembly.
3 Assess the Severity of Consequences
Evaluate the impact level of each hazard For instance, reduced braking
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4 Determine the Probability of Occurrence
Analyze how likely each hazardous event is to occur, based on historical data, simulation results, or engineering judgment This probability may range from rare to highly likely.
5 Identify Effective Risk Control Measures
Develop preventive or corrective actions, such as improving material specifications, enhancing the thermal design of brake components, implementing stricter quality control processes, or providing driver training on brake usage.
A risk matrix visually assesses potential hazards by mapping hazardous events against their severity and likelihood Each intersection within the matrix is scored using qualitative or quantitative scales—like Low, Medium, or High—to accurately represent the corresponding risk level, facilitating effective risk management and decision-making.
Strict control on material selection and input quality standards is required
Thorough design simulation and testing before mass production
Strengthen quality control and standardize manufacturing processes.
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Consider environmental conditions during material selection and thermal design.
Provide detailed usage instructions and implement misuse monitoring systems
Design a proper maintenance cycle and replacement schedule to ensure performance
Recommendation
The brake system is a crucial component of a vehicle, with the brake disc rotor playing a vital role in ensuring effective stopping power Proper rotor design and analysis are essential for achieving optimal braking performance This study compares the performance of conventional, slotted, vented, and vented disc brake rotors, using AISI 5140 Steel for its superior thermal resistance and strong material properties The research concludes that selecting the appropriate rotor design and material enhances braking efficiency and safety, highlighting the importance of advanced rotor analysis in automotive engineering.
Drilled and vented disc brake rotors exhibited the lowest maximum recorded rotor temperatures, making them more effective at managing heat Slotted disc brake rotors followed, offering better thermal performance than standard drilled rotors Vented disc brake rotors also demonstrated improved heat dissipation, while drilled disc brake rotors recorded the highest maximum temperatures among the types analyzed.
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Stress and strain are directly related to temperature distribution, with their patterns reflecting the thermal profile across the three rotor designs Importantly, the stress and strain values observed are below the thresholds specified by Display standards, indicating that the designs operate within safe thermal limits This correlation emphasizes the significance of thermal management in optimizing rotor performance and ensuring compliance with industry standards.
The results clearly show that modifying the surface geometry by drilling and slotting provides more surface area for heat dissipation.
AISI 5140 steel is considered the optimal material for brake discs due to its superior ability to withstand thermal and electrostatic loads This steel's high durability and heat resistance make it ideal for ensuring reliable brake performance under demanding conditions Choosing AISI 5140 steel for brake discs enhances safety and longevity, making it a preferred choice in brake system engineering.
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REFLECTION
Alignment with ABET Student Outcomes
This project addresses a critical challenge in automotive engineering by focusing on enhancing brake disc performance to improve safety and efficiency Specifically, it aims to optimize heat dissipation, increase durability, and boost braking efficiency, aligning with ABET Student Outcome 3: problem-solving skills By tackling these key issues, students develop essential engineering competencies in analyzing complex problems and devising effective solutions, preparing them for real-world automotive applications.
A systematic approach is used to define constraints such as weight, material properties, thermal resistance, and manufacturability.
- Applying Engineering Principles to Develop Solutions: The design adhered to constraints such as economic (budget), environmental (material recyclability), and social (safety improvements).
-Considering Constraints and Real-World Factors:
The design process accounts for economic, environmental, and safety constraints by optimizing material selection and ensuring compliance with automotive safety standards.
Manufacturing feasibility is evaluated to ensure that the proposed design can be produced using conventional machining and casting techniques.
- Use of Modern Engineering Tools
Advanced engineering software tools, including MATLAB Simulink for system- level analysis, enhance the problem-solving approach.
Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) simulations validate the design's effectiveness under real-world conditions.
Various brake disc configurations, including drilled, slotted, vented, and hybrid designs, are explored to determine the optimal solution.
A decision matrix systematically compares design alternatives based on performance, cost, manufacturability, and durability.
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Physical testing, including braking efficiency tests, thermal performance evaluation, and wear analysis, ensures that the design meets performance expectations.
The results from simulations and real-world tests are compared to refine and validate the final design.
- Effective Communication and Team Collaboration
The project involves detailed documentation and presentations, demonstrating the ability to convey technical findings effectively.
Collaborative teamwork is emphasized through regular meetings, task delegation, and peer reviews to enhance problem-solving efficiency.
This project aligns closely with ABET's student outcomes by emphasizing robust problem-solving skills It ensures that graduates are well-prepared to address real-world engineering challenges through comprehensive educational strategies By focusing on these aspects, the project demonstrates a strong commitment to developing competent engineers capable of tackling practical problems effectively.
Reflection on the Engineering Design
The project adhered to an iterative engineering design methodology, integrating theoretical knowledge with practical application Key aspects are included:
- Identifying Opportunities: Addressing inefficiencies in the braking system vehicles, particularly optimizing heat dissipation, structural integrity, and braking efficiency.
Establishing design criteria aligned with automotive safety regulations and industry standards.
Defining constraints such as material selection, weight reduction, thermal stability, and manufacturability.
Conducting computational simulations using FEA and CFD to evaluate stress distribution, heat dissipation, and mechanical integrity of brake disc designs.
Analyzing material properties of AISI 5140 steel and Grey cast iron to determine optimal thermal and structural performance.
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Exploring and comparing different brake disc configurations, including drilled, slotted, vented, and hybrid designs.
Employing a decision matrix to assess alternatives based on key performance indicators such as heat dissipation, durability, manufacturability, and cost.
Ensuring that the selected design meets performance targets, regulatory compliance, and manufacturability constraints.
Validating the effectiveness of the final design through numerical analysis.
- Considering Risks and Trade-offs
Balancing weight reduction with structural strength and thermal efficiency.
Addressing potential failure modes such as thermal cracking and wear resistance to enhance durability.
Work efficiently to streamline the design process.
Engaging with faculty advisors and industry professionals for continuous feedback and improvement.
The importance of iterative testing and refinement in optimizing design performance.
Gaining hands-on experience with advanced engineering tools such as CATIA V5, ANSYS, and MATLAB Simulink.
Understanding the complexities of balancing multiple design constraints while ensuring compliance with safety regulations.
Overall, the graduation project provides a valuable learning experience in applying engineering principles to real-world automotive industry challenges, enhancing
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Earlier courses supporting design experience
The design experience gained in this project was strongly supported by foundational coursework, offering essential theoretical and practical knowledge Key courses played a crucial role in shaping the methodology and enhancing the overall outcomes of the project.
The Strength of Materials course provided me with essential knowledge on how various materials respond to mechanical loads such as tension, compression, shear, bending, and torsion I gained skills in calculating stress, strain, and deformation, enabling me to analyze the structural behavior of mechanical components effectively The course covered critical concepts like stress-strain relationships, material properties, and the importance of safety factors in design This foundational understanding was instrumental in my graduation project, where I evaluated the structural integrity of a brake disc to ensure it could endure the mechanical stresses during braking.
Which was critical for evaluating the mechanical integrity of the brake disc under different loading conditions.
- Thermodynamics and Heat Transfer - VEE703015:
Thermodynamics and Heat Transfer are essential for designing effective braking systems, as they explain the energy transformation and heat dissipation processes involved Thermodynamics helps us understand how a vehicle's kinetic energy converts into thermal energy through friction, affecting temperature and pressure within brake components while ensuring energy conservation and analyzing fluid behavior in hydraulic brakes Heat Transfer is crucial for studying how heat generated during braking is effectively dissipated from brake pads, discs, and drums through conduction, convection, and radiation, preventing excessive temperature rise that can lead to brake fade or material failure These principles inform the selection of materials and cooling mechanisms like ventilated discs and cooling fins to maintain optimal brake performance and safety.
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Introduced principles of heat dissipation, which were applied in the analysis of brake disc thermal performance.
CFD simulations were utilized to optimize airflow over the brake rotors, ensuring efficient cooling and reduced thermal degradation.
- Computer-Aided Design (CAD) and Finite Element Analysis (FEA) - MEM703005
The Computer-Aided Design (CAD) and Finite Element Analysis (FEA) course equipped me with essential skills in designing and analyzing mechanical components using advanced engineering software By mastering CAD tools like CATIA and SolidWorks, I gained the ability to create precise 3D models and conduct detailed simulations, enhancing my capabilities in mechanical design and engineering analysis.
I learned to create detailed 2D drawings, develop 3D models, and assemble mechanical systems, gaining practical experience in CAD design The course also introduced me to FEA simulation tools like ANSYS, allowing me to perform structural and thermal analyses under various loading conditions I developed skills in meshing, applying boundary conditions, and interpreting simulation results to evaluate stress, deformation, and heat distribution in mechanical components These competencies were directly applied in my graduation project, where I modeled a brake disc and assessed its performance under realistic braking scenarios, demonstrating my ability to apply advanced engineering simulations to real-world problems.
Training in CATIA V5 and ANSYS facilitated precise modeling, simulation, and validation of design iterations.
Enabled efficient evaluation of stress distribution and deformation under braking loads.
- Fundamentals of Vehicle Dynamics - VEE702045:
The Fundamentals of Vehicle Dynamics course provided essential knowledge about how vehicles behave under different driving conditions Key forces such as rolling resistance, aerodynamic drag, traction, and braking forces are crucial for understanding vehicle performance The course covered important concepts like weight transfer during acceleration and braking, and the dynamics of understeer and oversteer during cornering, which are vital for vehicle handling It also emphasized the role of suspension systems in maintaining vehicle stability and ride comfort, along with how tire characteristics impact grip and handling.
Using simplified dynamic models like the bicycle model for internal purposes at Phenikaa University provided essential insights into vehicle motion analysis This knowledge was particularly valuable for my graduation project, enabling accurate calculations of braking forces, detailed analysis of weight distribution, and comprehensive evaluation of the prototype car's dynamic performance.
Provided insight into braking system performance, helping to determine the optimal disc geometry and material selection.
Assisted in defining braking force calculations and overall system integration within the vehicle.
Knowledge of CNC machining, casting, and material selection ensured that the final design was manufacturable and cost-effective.
The Manufacturing Technology course equipped me with essential knowledge of both traditional and advanced production processes, including machining, CNC, EDM, and laser cutting It provided insights into metal forming techniques like casting, forging, welding, and stamping, helping me select suitable materials and manufacturing methods based on design, cost, and feasibility The course also highlighted the importance of quality control, equipment maintenance, and workplace safety, which were crucial in successfully executing my graduation project—particularly in evaluating brake disc manufacturability and identifying the best fabrication methods.
- Numerical Modeling and Analysis - VEE703001:
The Numerical Modeling and Analysis course equipped me with essential skills to solve complex engineering problems using numerical methods, including building mathematical models of physical systems I gained practical experience applying techniques like the Finite Element Method (FEM) to analyze stress, deformation, and heat transfer, enhancing my understanding of structural and thermal behavior Additionally, the course introduced me to powerful tools such as MATLAB, enabling me to simulate real-world scenarios and accurately interpret computational results, which are crucial for advanced engineering analysis.
This internal use copy from Phenikaa University was directly applied to my graduation project, where I utilized advanced simulation software to model and analyze the thermal and structural behavior of a brake disc The insights gained through this research helped optimize the brake disc's design and enhance its overall performance.
By integrating concepts from these earlier courses, the project team effectively developed an optimized brake disc design that meets safety, performance, and manufacturability criteria.
Complex engineering problems
The design and development of the brake disc system involve multiple characteristics of complex engineering problems, as described below:
The project involves addressing diverse and often conflicting technical challenges, such as optimizing heat dissipation, mechanical strength, weight reduction, and manufacturability Balancing these factors is complex because improvements in one area, like increasing thermal efficiency, can negatively impact others, such as adding weight and compromising overall vehicle performance Effective engineering solutions must carefully navigate these trade-offs to achieve optimal results.
This project adopts an innovative brake disc design that departs from traditional, established methods, requiring an iterative development process Multiple design alternatives were explored and evaluated through advanced simulations such as Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) to determine the most effective solution.
The design of the brake disc involves diverse stakeholders such as automotive engineers, manufacturers, regulatory authorities, and end-users, ensuring that all perspectives are incorporated This comprehensive approach balances cost-effectiveness, safety, and performance to meet the varying demands of the industry Considering multiple stakeholder needs is essential for developing brake discs that optimize safety, efficiency, and user satisfaction.
- Having significant consequences in a range of contexts: Brake disc failure or inefficiency can lead to safety hazards, including longer stopping distances, overheating, and mechanical failure The project addresses these risks by ensuring reliability under varying road and environmental conditions, thereby enhancing overall vehicle safety and regulatory compliance.
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Engineering Design: Factors and Considerations
The development of brake disc design required a comprehensive, multidisciplinary approach that prioritized public health, safety, and welfare while considering global, cultural, social, environmental, and economic factors Ensuring the reliability and efficiency of the braking system was crucial to prevent accidents, which was achieved by optimizing heat dissipation and strengthening structural integrity to withstand high temperatures and mechanical stress Materials selected for their resilience contributed to long-term performance and safety in real-world driving conditions Welfare concerns were addressed by enhancing braking performance cost-effectively and reducing brake dust emissions, which help mitigate environmental pollution and protect respiratory health Overall, the project aimed to improve vehicle safety, environmental sustainability, and accessibility for a broad range of users.
Environmental impact plays a vital role in brake disc material selection, emphasizing sustainability, recyclability, and environmental safety Eco-friendly surface treatments and low-emission manufacturing methods are prioritized to reduce the carbon footprint Additionally, simulation-driven design enables optimization of manufacturing efficiency and minimizes material waste during machining and casting processes, supporting environmentally conscious production.
Economic factors were crucial in this project because it was based on a prototype vehicle These prototypes typically incur high research and development costs but do not benefit from economies of scale or generate direct revenue since they are not mass-produced The true economic value of such projects resides in indirect benefits, including improving brand reputation, validating emerging technologies, and paving the way for future commercialization.
This internal report at Phenikaa University highlights market strategies based on insights from a brake disc design project Although short-term profitability is limited, the valuable knowledge gained provides significant long-term strategic advantages.
Potential impacts
The design of brake discs plays a crucial role in improving global vehicle safety standards and promoting the adoption of optimized braking solutions across international markets Economically, innovative brake disc designs make advanced braking systems more affordable, supporting job creation in engineering and manufacturing sectors Environmentally, these designs reduce material waste and brake dust emissions, enhancing product durability and lowering ecological impact Societally, improved brake disc technology contributes to enhanced road safety and fosters sustainable automotive engineering, paving the way for safer and greener transportation solutions.
General reflection
Throughout the project, overcoming challenges such as cracking in the initial brake disc loop design required innovative solutions, including optimizing material composition and disc geometry This process fostered critical thinking, adaptability, and enhanced skills in CAD modeling, simulation, material analysis, and testing Regular progress tracking and effective teamwork ensured smooth development and timely problem resolution, with iterative design and validation crucial in refining the final product Exposure to industry-standard tools like ANSYS and CATIA provided practical experience, emphasizing the importance of balancing performance, cost, and manufacturability in engineering design.
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This project successfully achieved its objective of designing and analyzing an optimized braking system for a student prototype car, addressing the unique constraints of lightweight construction, thermal performance, and manufacturability.
A comprehensive evaluation of various brake disc configurations—including drilled, slotted, vented, and combined drilled and vented designs—revealed that the drilled and vented brake disc is the most effective solution This design offers superior thermal dissipation, minimizing heat buildup during braking Additionally, it reduces stress and deformation, ensuring enhanced durability Overall, the drilled and vented brake disc maintains excellent structural integrity under simulated braking conditions, making it the optimal choice for improved brake performance.
Advanced materials such as SiCₙ/6061 Al composite and AISI 5140 steel were thoroughly tested for their superior mechanical and thermal properties, playing a crucial role in reducing brake disc weight while improving strength and heat resistance The optimized design achieved over a 20% reduction in brake disc mass, effectively maintained operating temperatures below critical limits, and ensured full compliance with safety standards for reliable performance.
Integrating engineering software like CATIA V5, ANSYS, and MATLAB Simulink with thorough testing and validation provides a comprehensive, real-world approach to solving complex automotive engineering problems This process enhances technical problem-solving skills while preparing students for future professional practice in the automotive industry.
The recommended approach for prototype applications is to adopt drilled and vented disc configurations, which enhance cooling and braking performance Future improvements should focus on material innovation and advanced manufacturing techniques to optimize durability and efficiency Additionally, conducting comprehensive real-world performance testing is essential to validate design improvements and support the evolution of braking system technologies.
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1 Srinivasan, N., et al (2022) Design development and optimization of disc brake using generative design on Fusion 360 InAIP Conference Proceedings.
2 Singh, M., et al (2023) Design and analysis of an automobile disc brake rotor by using hybrid aluminium metal matrix composite for high reliability.Journal of Composites Science, 7(6), 244.
3 Maleque, M., Dyuti, S., & Rahman, M (2010) Material selection method in design of automotive brake disc In Proceedings of the World Congress on Engineering.
4 Saravanan, B (2015) Design and analysis of disc brake rotor International Journal of Applied Engineering Research, 10(19.
5 Thông số kỹ thuật xe ô tô Infiniti prototype 9 Available from: https://xezii.com/xe-prototype?lang=vi.
6 Baskara Sethupathi, P., et al (2015) Numerical analysis of a rotor disc for optimization of the disc materials Journal of Mechanical Engineering and Automation, 5(3B), 05-14.
7 Talati, F., & Jalalifar, S (2009) Analysis of heat conduction in a disk brake system.Heat and Mass Transfer, 45(8), 1047-1059.
8 Belhocine, A., & Bouchetara, M (2012) Thermal analysis of a solid brake disc.
9 Zhu, Z.-C., et al (2009) Three-dimensional transient temperature field of brake shoe during hoist's emergency braking Applied Thermal Engineering, 29(5-6),
10.Pevec, M., et al (2010) Numerical temperature analysis of brake disc considering cooling.Advanced Engineering, 4(1), 55-64.
Jiang et al (2012) conducted a comprehensive thermal analysis of SiC/6061 Al alloy co-continuous composite brake disks used in CRH3 trains during emergency braking, emphasizing the critical role of airflow cooling in heat dissipation Their study highlights how the composite material's thermal properties influence brake disk performance under high-temperature conditions The research provides insights into optimizing brake disk design to enhance safety and efficiency during rapid deceleration By analyzing airflow cooling effects, the study offers valuable data for improving thermal management strategies for high-speed train braking systems Overall, this work advances understanding of thermal behavior in composite brake disks, contributing to safer and more reliable high-speed rail operations.
12.Radhakrishnan, C., et al (2015) Design and analysis of disc brake with titanium alloy International Journal of Innovative Science, Engineering & Technology, 2(5), 1044-1050.
13.Shinde, V.V., Sagar, C.D., & Baskar, P (2014) Thermal and structural analysis of disc brake for different cut patterns International Journal of Engineering Trends and Technology, 11(2), 84-87.
14.Huang, Y.M., & Chen, S.-H (2006) Analytical study of design parameters on cooling performance of a brake disk.SAE Technical Paper.
15.S.R., et al (2023) Design and analysis of brake disc, PhD dissertation],
University of Science and Technology.
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