SWAMI KESHVANAND INSTITUTE OF TECHNOLOGY, MANAGEMENT & GRAMOTHAN,

JAIPUR
DEPARTMENT OF MECHANICAL ENGINEERING
DESIGN AND OPTIMIZATION OF DISC BRAKE ROTOR
OBJECTIVE
The project deals with design and topology optimization of a disc brake for an All-Terrain Vehicle with an objective of reduction in weight as compared to OEM discs.

DESIGN METHODOLOGY BRAKING SPECIFICATIONS DESIGN SPECIFICATIONS FINITE ELEMENT ANALYSIS

Tandem Master Bore dia. 20.63 mm

Concept Cylinder Stroke 25.40 mm
development Brake Caliper Fixed Type Dual Piston
Piston Stress Plot Deformation Plot
30 mm
Diameter Max. =131.84 MPa Max. = 0.014 mm
Market COF between
research 0.45
Pad and Disc

Material AISI 1040 (EN8) steel

Component Factor of safety Fatigue life
selection Outer diameter 150 mm Min. = 3.14 Min. = 1E6
Dynamic Static
Weight Weight Pitch circle
70 mm
Alternative diameter
Frictiona Braking Mass Designed 236 g
designs l Force Force Actual 250 g
Air Velocity Temperature
Max. = 32.67 m/s Max. = 219.01◦C
Analysis Brake Clamping
PROJECT OUTCOMES
Fail Torque Force
Pass • The design is validated using FEA Group No: 2018 A 09
Group Members:
Select best Brake Force on
methods and successfully installed in ATV.
Deepansh Mathur
available Line Pr. TMC • About 50% reduction in weight as Anshul Maheshwari(L)
option compared to OEM disc (Used in Hero E- Abhishek Sharma
Sprint). Aniruddh Singh
Pedal
Force
Leverage • The required braking torque is generated Guide:
to lock the wheels at speed of 16.6 m/s. Mr. Chndan Kumar