Design and Dynamic Analysis of Metal Matrix Composite-Based Disc Brake Pads for Formula Cars

Anand Pai; Vineet Maheshwari; S. V. Shivaditya; Ravindra Mallya; Satish Shenoy Baloor

doi:10.1007/s40032-025-01231-7

Design and Dynamic Analysis of Metal Matrix Composite-Based Disc Brake Pads for Formula Cars

Anand Pai
, Vineet Maheshwari
, S. V. Shivaditya
, Ravindra Mallya
, Satish Shenoy Baloor^*

^*Corresponding author for this work

Research output: Contribution to journal › Article › peer-review

Abstract

This study focuses on the design of disc brake and dynamic analysis of metal matrix composite (MMC)-based disc brake pads for a small car, using a representative volume element (RVE) approach. The brake caliper for the Formula car was designed based on the principles of vehicle dynamics. Following this, the brake pad was designed to suit the caliper. For the brake pad friction block, a ceramic particle reinforced AA6061 matrix composite was used. B4C particles (5 wt%) served as the ceramic reinforcements. A suitable mesoscale RVE model was developed in ANSYS Design Modeler^® software to compute the material properties, which were then applied to the macro model of the brake pad for dynamic analysis using the Explicit dynamics tool^®. In this analysis, the oppositely positioned brake pads were held against the counter disc under a compressive force equal to the clamping force of the front caliper piston. The brake pad performance in terms of von Mises stress, equivalent elastic strain during the dynamic analysis, the sliding velocity, interface pressure, and frictional heating characteristics were studied in detail. The analysis demonstrated the effectiveness of using an RVE-based approach for accurately predicting the dynamic performance and thermo-mechanical behavior of MMC-based brake pads.

Original language	English
Pages (from-to)	1455-1467
Number of pages	13
Journal	Journal of The Institution of Engineers (India): Series C
Volume	106
Issue number	5
DOIs	https://doi.org/10.1007/s40032-025-01231-7
Publication status	Published - 10-2025

All Science Journal Classification (ASJC) codes

Aerospace Engineering
Ocean Engineering
Mechanical Engineering
Industrial and Manufacturing Engineering

Access to Document

10.1007/s40032-025-01231-7

Cite this

@article{3a4a06dea3fa485092ac6b310f985108,

title = "Design and Dynamic Analysis of Metal Matrix Composite-Based Disc Brake Pads for Formula Cars",

abstract = "This study focuses on the design of disc brake and dynamic analysis of metal matrix composite (MMC)-based disc brake pads for a small car, using a representative volume element (RVE) approach. The brake caliper for the Formula car was designed based on the principles of vehicle dynamics. Following this, the brake pad was designed to suit the caliper. For the brake pad friction block, a ceramic particle reinforced AA6061 matrix composite was used. B4C particles (5 wt\%) served as the ceramic reinforcements. A suitable mesoscale RVE model was developed in ANSYS Design Modeler{\textregistered} software to compute the material properties, which were then applied to the macro model of the brake pad for dynamic analysis using the Explicit dynamics tool{\textregistered}. In this analysis, the oppositely positioned brake pads were held against the counter disc under a compressive force equal to the clamping force of the front caliper piston. The brake pad performance in terms of von Mises stress, equivalent elastic strain during the dynamic analysis, the sliding velocity, interface pressure, and frictional heating characteristics were studied in detail. The analysis demonstrated the effectiveness of using an RVE-based approach for accurately predicting the dynamic performance and thermo-mechanical behavior of MMC-based brake pads.",

author = "Anand Pai and Vineet Maheshwari and Shivaditya, \{S. V.\} and Ravindra Mallya and \{Shenoy Baloor\}, Satish",

note = "Publisher Copyright: {\textcopyright} The Author(s) 2025.",

year = "2025",

month = oct,

doi = "10.1007/s40032-025-01231-7",

language = "English",

volume = "106",

pages = "1455--1467",

journal = "Journal of The Institution of Engineers (India): Series C",

issn = "2250-0545",

publisher = "Springer",

number = "5",

}

TY - JOUR

T1 - Design and Dynamic Analysis of Metal Matrix Composite-Based Disc Brake Pads for Formula Cars

AU - Pai, Anand

AU - Maheshwari, Vineet

AU - Shivaditya, S. V.

AU - Mallya, Ravindra

AU - Shenoy Baloor, Satish

N1 - Publisher Copyright: © The Author(s) 2025.

PY - 2025/10

Y1 - 2025/10

N2 - This study focuses on the design of disc brake and dynamic analysis of metal matrix composite (MMC)-based disc brake pads for a small car, using a representative volume element (RVE) approach. The brake caliper for the Formula car was designed based on the principles of vehicle dynamics. Following this, the brake pad was designed to suit the caliper. For the brake pad friction block, a ceramic particle reinforced AA6061 matrix composite was used. B4C particles (5 wt%) served as the ceramic reinforcements. A suitable mesoscale RVE model was developed in ANSYS Design Modeler® software to compute the material properties, which were then applied to the macro model of the brake pad for dynamic analysis using the Explicit dynamics tool®. In this analysis, the oppositely positioned brake pads were held against the counter disc under a compressive force equal to the clamping force of the front caliper piston. The brake pad performance in terms of von Mises stress, equivalent elastic strain during the dynamic analysis, the sliding velocity, interface pressure, and frictional heating characteristics were studied in detail. The analysis demonstrated the effectiveness of using an RVE-based approach for accurately predicting the dynamic performance and thermo-mechanical behavior of MMC-based brake pads.

AB - This study focuses on the design of disc brake and dynamic analysis of metal matrix composite (MMC)-based disc brake pads for a small car, using a representative volume element (RVE) approach. The brake caliper for the Formula car was designed based on the principles of vehicle dynamics. Following this, the brake pad was designed to suit the caliper. For the brake pad friction block, a ceramic particle reinforced AA6061 matrix composite was used. B4C particles (5 wt%) served as the ceramic reinforcements. A suitable mesoscale RVE model was developed in ANSYS Design Modeler® software to compute the material properties, which were then applied to the macro model of the brake pad for dynamic analysis using the Explicit dynamics tool®. In this analysis, the oppositely positioned brake pads were held against the counter disc under a compressive force equal to the clamping force of the front caliper piston. The brake pad performance in terms of von Mises stress, equivalent elastic strain during the dynamic analysis, the sliding velocity, interface pressure, and frictional heating characteristics were studied in detail. The analysis demonstrated the effectiveness of using an RVE-based approach for accurately predicting the dynamic performance and thermo-mechanical behavior of MMC-based brake pads.

UR - https://www.scopus.com/pages/publications/105009954545

UR - https://www.scopus.com/pages/publications/105009954545#tab=citedBy

U2 - 10.1007/s40032-025-01231-7

DO - 10.1007/s40032-025-01231-7

M3 - Article

AN - SCOPUS:105009954545

SN - 2250-0545

VL - 106

SP - 1455

EP - 1467

JO - Journal of The Institution of Engineers (India): Series C

JF - Journal of The Institution of Engineers (India): Series C

IS - 5

ER -

Design and Dynamic Analysis of Metal Matrix Composite-Based Disc Brake Pads for Formula Cars

Abstract

All Science Journal Classification (ASJC) codes

Access to Document

Other files and links

Fingerprint

Cite this