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The main problem of braking and stopping a bike is the extraordinary input of heat flux into the disc in a very short time. In the braking process, thermal stresses are generated by the frictional heat and thermal fatigue cracks appear due to the thermal stress on a braking surface. To improve disc brake cooling performance we propose a new design in ventilated brake disc. Also as there is a demand for lighter material, a newly developed stir casted master alloy (Al90%Ti5%Cr5%) has been proposed to be used as an alternative to conventional cast iron. Results of Thermal stress analysis of a aerofoil shaped ventilated cast iron disc have been compared with new proposed alloy disc with hexagonal shaped cut section and results has been encouraging. Both steady-state and transient simulations are performed using ANSYS CFX 14.5 based on the finite volume method and the time marching algorithm. The wear rate, coefficient of friction and contact pressure are derived from experimental measurements and applied to the computational designed model of the rotor. Both brake discs exhibit a similar temperature during initial period, while lower temperature is achieved by the new brake disc under steady-state conditions due to 1.82 times increase in heat transfer area caused by the hexagonal sections. Therefore Al MMC (80%Al 5%Ti 5%Cr with 10%SiC) with proposed hexagonal cut sectioned disc is most suitable for disc brake.

Design analysys of disk brake using newly developed stir casted master alloy disk for improved cooling