Fatigue failure of disc brake of motorcycle by comined loading

A disc brake is a brake that slows down the vehicle’s speed by the friction caused by the brake pads press against the rotating disc with a set of calipers. Disc rotor helps to dissipate the heat which caused by the friction especially under hard braking conditions. This project was performed to investigate the crack propagation of the rear disc brake of the KTM DUKE 390 motorcycle. Besides that, transient thermal analysis and static structural analysis were performed on the high performance motorcycle disc brake with the help of the temperature readings taken from the experimental setup.How the crack is propagated and were more stress will generate is shown after the simulation and analysis. The CAD model of the high performance motorcycle disc brake was created by using the CATIA software. Transient thermal analysis and static structural analysis were performed on the disc brake by using ANSYS software. The result of static structural analysis was interpreted in three aspects: stress, deformation and stress intensity factor(SIF). Cyclic loading of disc brake for the suitable material was also defined by simulation analysis. It was found that their is more stress and heatflux in the tip of the crack and mostly the crack occors on the vented/drilled disc brake.