Design and Analysis of Aluminium–SiC Composite Brake Disc Using ANSYS Workbench

Brake disc performance significantly influences vehicle safety, thermal stability, and structural reliability. Conventional grey cast iron discs provide acceptable mechanical strength but contribute to higher unsprung mass and thermal inefficiency. In this work, a numerical investigation of an Aluminium 6061–Silicon Carbide (Al–SiC) composite brake disc is carried out using ANSYS Workbench. Structural and steady-state thermal analyses were performed and compared against grey cast iron material. Finite element results indicate that the Al–SiC composite exhibits reduced von-Mises stress, lower peak temperature, improved heat dissipation capability, and superior strength-to-weight ratio. The study validates the feasibility of replacing conventional cast iron discs with lightweight metal matrix composite alternatives based purely on numerical simulation.