Projects

Modeled in SolidWorks using revolve, pattern, and cut features, the rotor was analyzed using static and thermal FEA to assess its mechanical integrity under braking forces and thermal load.

SolidWorks

Project brief

This project presents the design and structural analysis of a vented disc brake rotor for a high-performance vehicle. The part includes heat-dissipation slots and a symmetrical bolt pattern. Section views and part drawings highlight manufacturability and assembly fit.

industry

Drafting, modeling, and FEA

RESULTS

•Max stress: ≈ 4.15 × 10⁸ N/m² = 415 MPa (red zones) •Min stress: ≈ 1.56 N/m² (blue zones)

•High stress regions (red/orange) are likely contact points with the brake disc or load-application zones : these are critical areas to monitor for material yielding or fatigue. •Low stress zones (blue) indicate areas with little to no stress : the free or unloaded parts of the pad.

Displacement range: • Max: ≈ 1.13 mm • Min: ≈ near 0 mm

•Maximum deformation occurs along the sides and near the top edge where the purple arrows indicate force application. •The pad is deforming under compressive and possibly lateral forces, which is expected during braking. •A deformation of 1.13 mm could be acceptable or problematic depending on the tolerances between brake components.

Strain range: •Max: ≈ 4.16 × 10⁻³ = 0.00416 (dimensionless) •Min: ≈ 2.27 × 10⁻¹¹

•Equivalent strain indicates how much the material deforms per unit length. •A strain of 0.00416 (0.416%) is low to moderate : (usually) within elastic range for metals and composites. •Peak strain is in the same regions as the max displacement: this is a good correlation between the plots.