Structural and thermal analysis of disc brake rotor

Apart from normal braking system, disc brake is one of the most inevitable development in the automobile field. The function ofdisc brake rotor is to reduce the rotor speed quickly and stop the rotation in less time as compared to earlier braking system. During this process, due to the action between rotor and brake pads, stress and heat will be generated on the disc rotor. These parameters should be optimized such that the disc rotor is balanced for all operating conditions. In this paper for the purpose of modeling and analysis the specifications of Pulsar 150 cc engine bike is adopted. This analysis is carried at constant pressure of 1.5MPa and at constant speed of 2550rpm. Initially the structural and thermal analysis are done on existing design of Pulsar 150 cc disc rotor with grey cast iron material to assess the parameters such as deformation, stress, factor of safety, total temperature, heat flux. In the next phase in order to avail the advantage of heat dissipation the design was modified by increasing number of holes then analysis is repeated with same material and noticed improvement in Aluminium-7068. Further the modified design of disc brake rotor is analyzed for the same parameters by varying the materials such as stainless steel, Aluminium-7068. Finally parameters analyzed are evaluated and compared for best suitable design andmaterial