FEA on different disc brake rotors

In this report a study on a designed grooved-disc brake and combination of drilled and grooved disc brake rotor will be discussed. The effects of an applied linear load on each rotor will be presented. The project is aimed at determining the critical zones on both designs of disc brake systems that are subjected to different linear forces. The required parameters to determine these critical zones will be the load, stress concentrations and the displacement experienced. The brake systems are based on the design parameters of a Brembo brake rotor for a Renault type vehicle. Numerical and software analysis with different investigations is used to determine various parameters needed to be considered before testing could be complete. Observations on the stress vs load results, there is a gradual increase in the stress experienced on each section as the load is increased. This can be seen on section A-A of the drilled and grooved brake disc where a 20000N load was exerted with a stress of 57.2495MPa and the greatest load of 35000N was then applied with the greatest stress recorded at 100.1875MPa. The displacement vs load at each section were then determined. This showed an increase in displacement as the load exerted had increased. Extremely small displacements were experienced at Section B-B and C-C. These values can be negligible. Section B-B experienced a displacement of 0mm at 20000N and 0mm with a load of 35000N as these sections were fixed during the simulation. The greatest displacements were found to be at section A-A. Displacements ranging from 0.019386mm to 0.041395mm. This indicates that Section A-A is a critical zone. From the results obtained Section A-A is identified as a critical zone for both rotor designs and a point where the brake discs may fail initially. The grooved disc brake rotor was found to experience a greater stress concentration and displacement compared to the drilled and grooved disc brake rotor. This can be attributed to a flaw within the created design. The simulation allows these flaws and critical areas to be determined to better the required design without having to apply destructive testing on the disc brake rotor.