Abstract
One of the most common problems related to ventilated brake discs are crack formations, particularly under high brake loads or from the associated stresses during braking. In this study, three different ventilated brake discs, the crossdrilled disc, the cross-slotted disc, and the cross-slotted with a side groove disc, were manufactured, and their braking force performances were investigated experimentally together with a solid disc. Stress analyses were subsequently performed by the finite element method. Analyses results showed that the maximum stress generations were formed on the ventilated discs in comparison to the solid disc. However, these comparisons indicate that the application of varying force distributions along brake pads reduces the stresses on ventilated discs by 8.8% to 19.1%.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
References
Aleksendric, D., Duboka, C., Gotowicki, P. F., Mariotti, G. V. and Nigrelli, V. (2006). Braking procedure analysis of a pegs-wing ventilated disk brake rotor. Int. J. Vehicle System Modelling and Testing 1,4, 233–252.
Antanaitis, D. B. and Rifici, A. (2006). The effect of rotor crossdrilling on brake performance. SAE Paper No. 2006-01-0691, 571–596.
Bagnoli, F., Dolce, F. and Bernabei, M. (2009). Thermal fatigue cracks of fire fighting vehicles gray iron brake discs. Engineering Failure Analysis 16,1, 152–163.
Brecht, J. and GmbH, T. (1998). Influence of material selection on stresses in ventilated brake discs. SAE Paper No. 980595.
Breuer, B. and Bill, K. H. (2008). Brake Technology Handbook. 1st English Edn. SAE. Warrandale. Pennsylvania. USA.
Chatterley, T. C. and Macnaughtan, M. P. (1999). Cast iron brake discs-Current position, performance and future trends in Europe. SAE Paper No. 108, 1, 505–514.
Han, J. N., Cho, N. J., Chae, S. W. and Choi, Y. (2008). Hybrid three-dimensional mesh generation from quaddominant surface meshes. Int. J. Automotive Technology 9,5, 633–640.
Heisler, H. (1999). Vehicle and Engine Technology. 2nd Edn. SAE. Warrandale. Pennsylvania. USA. 235–237.
Hudson, M. D. and Ruhl, R. L. (1997). Ventilated brake rotor air flow investigation. SAE Paper No. 971033.
Kim, D. J., Lee, Y. M., Park, J. S. and Seok, C. S. (2008). Thermal stress analysis for a disk brake of railway vehicles with consideration of the pressure distribution on a frictional surface. Materials Science and Engineering A, 483–484, 456–459.
Limpert, R. (1999). Brake Design and Safety. 2nd Edn. SAE. Warrendale. USA. 140–143.
Liu, Y., Liu, L. and Mahadevan, S. (2007). Analysis of subsurface crack propagation under rolling contact loading in railroad wheels using FEM. Engineering Fracture Mechanics 74,17, 2659–2674.
Mackin, T. J., Noe, S. C., Ball, K. J., Bedell, B. C., Bim-Merle, D. P., Bingaman, M. C., Bomleny, D. M., Chemlir, G. J., Clayton, D. B. and Evans, H. A. (2002). Thermal cracking in disc brakes. Engineering Failure Analysis, 9, 63–76.
Patrick, G. S. (2002). An improved rotor for self-ventilating disc brakes. Int. Application Published under the Patent Cooperation Treaty (PCT), WO/2002/064992.
Ripley, M. I. and Kirstein, O. (2006). Residual stresses in a cast iron automotive brake disc rotor. Physica B: Condensed Matter, 385–386,1, 604–606.
Venkitachalam, G. and Maharudrappa, M. (2008). Flow and heat transfer analysis of a ventilated disc brake rotor using CFD. SAE Paper No. 2008-01-0822.
Zuber, Ch. and Heidenreich, B. (2006). Development of a net shape manufacturing mehod for ventilated brake discs in single piece design. Materialwissenschaft und Werkstofftechnik 37,4, 301–308.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Yildiz, Y., Duzgun, M. Stress analysis of ventilated brake discs using the finite element method. Int.J Automot. Technol. 11, 133–138 (2010). https://doi.org/10.1007/s12239-010-0018-0
Received:
Revised:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12239-010-0018-0