International Journal of Emerging Technology and Advanced Engineering Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 9, September 2013) 383 Modeling And Analysis of FSAE Car Disc Brake Using FEM V. Chengal Reddy 1 , M. Gunasekhar Reddy 2 , Dr. G. Harinath Gowd 3 1 PG Student, 2 Assistant Professor, 3 Professor, Department of Mechanical Engineering, MITS, Madanapalle. Andhra Pradesh., INDIA. Abstract — Braking is a process which converts the kinetic energy of the vehicle into mechanical energy which must be dissipated in the form of heat. The disc brake is a device for deaccelerating or stopping the rotation of a wheel. A brake disc (or rotor) usually made of cast iron or ceramic composites, is connected to the wheel and/or the axle. Friction material in the form of brake pads (mounted on a device called a brake caliper) is forced mechanically, hydraulically, pneumatically or electromagnetically against both sides of the disc to stop the wheel. The present research is basically deals with the modeling and analysis of solid and ventilated disc brake using Pro-E and Ansys. Finite element (FE) models of the brake-disc are created using Pro-E and simulated using ANSYS which is based on the finite element method (FEM). In this research Coupled Analysis (Structural & Thermal analysis) is performed in order to find the strength of the disc brake. In structural analysis displacement, ultimate stress limit for the design is found and in thermal analysis thermal gradients, heat flow rates, and heat fluxes to be calculates by varying the different cross sections, materials of the disc. Comparison can be done for displacement, stresses, nodal temperatures, etc. for the three materials to suggest the best material for FSAE car. Keywords— Disc Brake, Modeling, Ansys, Structural Analysis, Thermal Analysis I. INTRODUCTION A brake is a device by means of which artificial frictional resistance is applied to moving machine member, in order to stop the motion of a machine. In the process of performing this function, the brakes absorb either kinetic energy of the moving member or the potential energy given up by objects being lowered by hoists, elevators etc. The energy absorbed by brakes is dissipated in the form of heat. This heat is dissipated in to the surrounding atmosphere to stop the vehicle, so the brake system should have the following requirements: 1. The brakes must be strong enough to stop the vehicle with in a minimum Distance in an emergency. 2. The driver must have proper control over the vehicle during braking and the vehicle must not skid. 3. The brakes must have good ant fade characteristics i.e. their effectiveness should not decrease with constant prolonged application. 4. The brakes should have good anti wear properties. Based on mode of operation brakes are classified as follows:  Hydraulic brakes.  Electric brakes.  Mechanical brakes. The mechanical brakes according to the direction of acting force may be sub divided into the following two groups: 1. Radial brakes. 2. Axial brakes. 1). Radial brakes: In these brakes the force acting on the brake drum is in radial direction. The radial brake may be subdivided into external brakes and internal brakes. 2). Axial brakes: In these brakes the force acting on the brake drum is only in the axial direction. e.g. Disc brakes, Cone brakes. a) Disc brakes: A disc brake consists of a cast iron disc bolted to the wheel hub and a stationary housing called caliper. The caliper is connected to some stationary part of the vehicle, like the axle casing or the stub axle and is cast in two parts, each part containing a piston. In between each piston and the disc, there is a friction pad held in position by retaining pins, spring plates etc. passages are drilled in the caliper for the fluid to enter or leave each housing. These passages are also connected to another one for bleeding. Each cylinder contains rubber-sealing ring between the cylinder and piston. A schematic diagram is shown in the figure 1. Figure 1: Disc Brake