Structural evaluation of different materials of a brake disc for automotive applications

Abstract

The performance of the disc braking system is a critical parameter regarding safety in passenger vehicles. Among its components, the brake disc plays a major role since it should be able to withstand the loads generated by the friction with the brake pads. In this work, the resistance of different materials used in a ventilated brake disc was evaluated using the Finite Element Method. The ductile iron ASTM A536 Grade 80–55–06, the aluminum alloy LM30, and the titanium alloy Ti-6Al4V

were compared with the gray cast iron. The temperature distribution, and the development of Von Mises stress and deformation were determined by considering conditions of a vehicle braking event. Also, a modal study was performed to determine the influence of the materials on the vibration of the disc. The results allowed to evaluate the resistance of the disc, which was determined by the critical zones of the disc prone to failure, the deformation and the effectiveness of the materials to dissipate the heat. Also, a fatigue analysis of the disc was carried out by means of the safety factor and the useful life, which allowed to determine the feasibility of the materials to be used for the disc in automotive applications.