Comparing and Analysing the Static and Thermal Characteristics of Brake Disc for Three Different Materials

Disc brake is the customarily used braking system in automobiles. In the disc brake assembly, rotor is subjected to rotation and the brake pads are operated by the driver through mechanical action. So, the disc plays a decisive role in dropping the speed or stopping the vehicle. These discs were commonly made of cast iron conventionally. But the limitations with respect to cast iron are that they have less corrosion resistance and heavy in weight. In order to overcome the above-said complications, alternate materials for disc have to be found. The main objective of this paper is to analyze the characteristics of three different materials and their characteristics and recommend a fitting material that highly replaces the conventional material and has better performance at on-road braking conditions. In order to find an alternative material for Cast Iron (CI), EN31, Ti-6Al-4V(Ti alloy) acts as a potential candidate in offering great damping property and thermal conductivity with less density. So, a comparative study was done on conventional CI with that of EN31 alloy and-6Al-4V(Ti alloy). The chosen profile for analysis is the X-core structure. All three materials were analyzed under the same operating conditions and their statistical and thermal behaviour was found out. In addition to that, their heat flux, von mises stress, and deformation characteristics were also recorded. The best material under von mises stress is cast iron, for heat flux is Ti-6Al-4V (Ti alloy) and for deformation the best material is EN31. From the results obtained, it was found out that with respect to the heat flux and deformation, Ti-6Al-4V and EN31 respectively yields better results when compared with the CI material.