Structural analysis on mild-steel and aluminium brake disk for application on belt conveyor

A disk brake system has three essential functions, namely, reducing the moving conveyor speed, preserving its steady downhill speed and stopping the conveyor fully during normal or emergency operation. There has been a persistent demand in recent years for light weight disks with highly efficient energy-absorbing structures and materials in the overall conveyor system. This aspiration has led to experimental work in attempt to use various materials for engineering designs. In this article, a rotating annular disc subjected to in-plane frictional loads is analytically modelled on the brake system. In order to obtain modal properties of breaking for inputs into the finite element model, the experimental modal test of disc brake device free under free boundary conditions is performed. The goal of this research is to recognize various properties that may in future enable us to optimize working parameters and increase braking system efficiency. The findings will enable us to achieve the optimal functionality of this structure to improve the operational disc life or performance. The aim of this document is to examine stress concentration, structural deformation and brake disk contact pressure during a single braking stop event using ANSYS 19.2 academic finite element software. This research therefore provides an important guide to the design and engineering of the brake disk and the brake pad. Structural and stress analysis are therefore preferred to pick the lightweight material for improved performance. Consequently, the lightweight material may be recommended to reduce the conveyor working load and preserve operational energy consumption, provided that light weight will satisfy working duty requirements. Comparing the results achieved with those of the technical literature, the simulation is satisfactory.