Thermo-mechanical performance evaluation of motorcycle disc brake rotors using finite element analysis

Abstract

Disc brake rotors are essential safety components in motorcycles, where their thermo-mechanical behavior under dynamic braking directly influences performance, durability, and reliability, particularly at high speeds. Conventional Gray cast-iron rotors, although widely used, often suffer from excessive thermal stress, significant deformation, and inadequate heat dissipation under severe braking conditions. Aluminium metal matrix composites (AMMCs) present advantages such as reduced weight and enhanced strength but encounter challenges including thermal expansion mismatch, localized stress concentration, and instability at elevated speeds. Despite their potential, few studies have explored microstructural tailoring of AMMCs to optimize their thermo-mechanical performance for practical braking applications. To address this, the present study systematically modifies AMMC constituents by incorporating tungsten carbide (WC) reinforcement while proportionally reducing aluminium content. A solid drilled disc rotor from a Bajaj Pulsar 150 cc was modeled in ANSYS Workbench and analyzed under transient coupled-field conditions across four braking speeds (800–2000 rpm). The work integrates transient Finite Element Analysis with experimental validation to compare Gray Cast Iron and three AMC formulations. Increasing WC reinforcement by 2% and reducing aluminium content improved thermal conductivity, hardness, and wear resistance while minimizing stress and deformation. Simulation and experimental results revealed that Gray Cast Iron experienced higher stress and temperature rise, whereas modified AMC2 demonstrated superior performance with lower peak temperatures, stable stress distribution, and minimal deformation. These findings highlight modified AMC2 as a promising material for next generation high-performance brake rotors, offering enhanced safety, durability, and weight efficiency.