Comparative Analysis of Disc Brake Using Eco-Friendly Material

Year : 2025 | Volume : 13 | Special Issue 06 | Page : 532 544
    By

    Shaik. Nagoor Baba,

  • G. Diwakar,

  • Charan Gopi Krishna Kondapalli,

  1. M. Tech. Student, Department of Mechanical Engineering, Koneru Laksmaiah Education Foundation, Vaddeswaram, Guntur, Andhra Pradesh, India
  2. Professor, Department of Mechanical Engineering, Koneru Laksmaiah Education Foundation, Vaddeswaram, Guntur, Andhra Pradesh, India
  3. M. Tech. Student, Department of Mechanical Engineering, Koneru Laksmaiah Education Foundation, Vaddeswaram, Guntur, Andhra Pradesh, India

Abstract

Brakes are crucial components for slowing or stopping the vehicle. Almost all vehicles use disc brakes. The working of a disc brake is simple; when the brake pedal is pressed, braking pads are forced mechanically against the rotor or disc on both surfaces. The friction generated between the rotor and brake pads slows down the vehicle. The design and materials of disc brakes play a significant role in their performance. Disc brake may fail due to various mechanical and thermal stresses. This problem can be overcome by choosing the right material and design. The primary aim of this research paper is to develop and examine the stresses on the disc brake by selecting environmentally friendly materials and design. Here, we have designed different models of disc brakes to reduce the weight of the disc and ensure good strength and stiffness. Gray cast iron is a conventional material used for making disc brakes. Though it has good thermal conductivity and strength, there are certain drawbacks, such as high weight and corrosion susceptibility. So, we have chosen Fly Ash & Aluminium as an alternative material for the disc brake. Three different models-Solid disc, Straight Vented, and Curved Vented were designed using Fusion 360 software. Structural and thermal analyses were performed on each design using ANSYS software. Total deformation, equivalent stress, and total heat flux were found in the analysis. After reviewing the outcomes, the optimal design and material for the disc brake have been selected. The findings suggest that disc brakes with Fly Ash Aluminium are the most viable and sustainable alternatives to gray cast iron.

Keywords: Disc brake, Gray Cast Iron, Fly Ash Aluminium Composites, Fusion 360, ANSYS

[This article belongs to Special Issue under section in Journal of Polymer & Composites (jopc)]

How to cite this article:
Shaik. Nagoor Baba, G. Diwakar, Charan Gopi Krishna Kondapalli. Comparative Analysis of Disc Brake Using Eco-Friendly Material. Journal of Polymer & Composites. 2025; 13(06):532-544.
How to cite this URL:
Shaik. Nagoor Baba, G. Diwakar, Charan Gopi Krishna Kondapalli. Comparative Analysis of Disc Brake Using Eco-Friendly Material. Journal of Polymer & Composites. 2025; 13(06):532-544. Available from: https://journals.stmjournals.com/jopc/article=2025/view=234864


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Special Issue Subscription Original Research
Volume 13
Special Issue 06
Received 16/08/2025
Accepted 15/09/2025
Published 25/09/2025
Publication Time 40 Days
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