Selection of material through "Thermal-Stress" analysis on Fusion 360 for a brake rotor

Abstract

The braking systems are used for reducing speed or halting the vehicle. The brake rotors experience high frictional forces causing their wear and tear; kinetic energy is converted into heat energy which increases the temperature of the rotor. If an appropriate amount of heat is not dissipated it can deteriorate the quality of the rotor. This paper aims to determine better material from the traditionally used Grey Cast Iron. Heat dissipation, deformation and safety factor are determined by the physical and thermal properties of the material. To select the best material, ‘Thermal-Stress’ analysis is performed on Fusion 360 as a brake rotor experiences not only high torque but also high temperature at the same time. The results are conferred based on the various criteria discussed in the paper such as material properties, the temperature generated and FEA. The tests lead to Ti-6Al-4V (Ti Grade 5) as the best material.