Computer aided design and finite element analysis of a brake caliper assembly

The following work studies a fairly new design and analysis technology of disc brake system. Disc brakes offer higher performance braking, simpler design, lighter weight, and better resistance to water interference than drum brakes. The methods incorporated to improve the design of the new caliper were the reduction in mass and improving the stress distribution thereby reducing the displacement. The reduction in mass is responsible for the vehicle stability as the brake caliper is mounted on the steering knuckle. An attempt is made to model the new caliper design for NASCAR racing and analyze the model for stresses and displacement using temperature effects.; The braking action for a disc brake is achieved when a high speed rotor comes in contact with the stationary stator i.e. the brake pad. So it is vital to analyze the behaviour of the braking system. A dynamic contact analysis of the brake rotor and pad is carried out to evaluate the contact forces and study the pressure distribution. The pressure distribution on the brake pad is further studied with the work done by Farzad Samie, David C. Sheridan. These forces and the pressure distribution are essential for the design of the brake pads and the braking system.