Design and Analysis of Disk Brake System

IJSRD - International Journal for Scientific Research & Development| Vol.4, Issue 04, 2016 | ISSN (online): 2321-0613

Design and Analysis of Disk Brake System Nitin Chandekar1 Ganpat Lal Rakesh2 1 M.Tech Student 2Assistant Professor 1,2 Christian College of Engineering and Technology, Kailash Nagar, Bhilai, India Abstract— The objective of this project is to improvise the properties of disk brake by performing structural and thermal analysis on different materials so as to increase the reliability of disk brake and also its service life. This can be done by reducing excess amount of stresses developed in disk brakes which would help in reducing various problems such as scarring, cracking, rusting etc. The ventilated brake disc assembly is built by a 3D Model in CREO and imported to ANSYS to evaluate the stress fields and of deformations which are established in the disc with the pressure on the pads and in the conditions of tightening of the disc.

Key words: Brake Discs, Pads, Heat flux, Heat transfer coefficient, Von Mises stress

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manufacturers and is developed by PTC. The suite consists of apps, each delivering a distinct set of capabilities for a user role within product development.

In order to research relationship between stiffness, mass and design variables, common batch file is built by CREO.

I. INTRODUCTION In today’s world competition in Automobile industry is growing day by day. A good braking system plays an important role in good performance. A disk brake is a device for slowing or stopping the rotation of wheel. A disk brake is usually made of cast iron or other composites of ceramic.

A friction material in the form of brake pads is forced against both side of the disks, causing the wheel to slow down or stop. A friction pad generates frictional force to reduce the movement.

Fig. 2: Dimensions of Brake III. GEOMETRY Bounding Box Length X 240. Mm Length Y 240 mm Length Z 4. mm Statistics Nodes 32928 Elements 13910 Analysis Type 3-D Table 1:

Fig. 1: Components of Disk Brake II. METHODOLOGY        

Identifying function of disk brake and its parts.

Discussing the performance of the disk brake and the microstructure of the friction pad.

Developing a solid model for the disk brake using CREO 3.0.

Developing a Steady state thermal analysis and structural analysis on Grey cast Iron, Aluminum alloy, Cast Iron and Carbon Ceramic Calculating the results.

Validation of results.

Design Of Disk Brake CREO is a family or suite of design software supporting product design for discrete

A. Thermal Analysis A thermal analysis calculates the temperature distribution and related thermal quantities in a system or components.

Typical thermal quantities of interest are:  The temperature distributions  The amount of heat lost or gained  Thermal gradients  Thermal fluxes The ANSYS program handles all three primary modes of heat transfer: conduction, convection, and radiation.

B. Structural Analysis Structural analysis is probably the most common application of the finite element method. The term structural (or structure) implies not only civil engineering structures such as bridges and buildings, but also naval, aeronautical, and mechanical structures such as ship hulls, aircraft bodies, and machine housings, as well as mechanical components such as pistons, machine parts, and tools.

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Design and Analysis of Disk Brake System (IJSRD/Vol. 4/Issue 04/2016/187)

C. Analysis Details of Research Paper Disc Dimension : 240mm Maximum Temperature : 350 °C Maximum Pressure : 1Mpa Normal force : 500 N Heat flux : 33.585 kw/m2 Thermal Gradient : Heat Flux / Thermal Conductivity = 33.582*103/40 = 839.63 k/m Velocity : 27.77 m/s Mass : 132 kg D. Materials Selected    

Fig. 4:

Aluminum Alloy Cast Iron Grey Cast Iron Carbon Ceramic

C. Cast Iron 1) Steady-State Thermal Object Temperature Name

IV. ANALYSIS DETAILS A. Aluminum Alloy 1) Steady-State Thermal Object Name

Minimum

Maximum

Temperature

Total Heat Flux

Directional Heat Flux

9.8884e 51.12 °C -002 W/mm² 9.8996e 65.041 0.10207 -002 °C W/mm² W/mm² Table 2: Steady-State Thermal 4.4231e004 W/mm²

Ther mal Error

Total Directional Heat Flux Heat Flux 4.8852e-7.3614eMinimum 25.282 °C 005 002 W/mm² W/mm² 7.5566e7.3579eMaximum 85.251 °C 002 002 W/mm² W/mm² Table 4: Steady-State Thermal

1.1001e -006

11.832

Fig. 5: D. Carbon Ceramic 1) Steady-State Thermal Object Temperature Name Minimum Fig. 3: B. Gray Cast Iron 1) Steady-State Thermal Object Temperature Name Minimum Maximum

Maximum

Total Heat Directional Flux Heat Flux 2.0471e-004 -8.6894e-002 36.808 °C W/mm² W/mm² 8.9606e-002 8.6894e-002 71.808 °C W/mm² W/mm² Table 5: Steady-State Thermal

Total Heat Directional Flux Heat Flux 2.4796e-004 -8.9496e-002 39.896 °C W/mm² W/mm² 9.2425e-002 8.9508e-002 70.066 °C W/mm² W/m Table 3: Steady-State Thermal

Fig. 6:

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Design and Analysis of Disk Brake System (IJSRD/Vol. 4/Issue 04/2016/187)

V. MESHING

Aluminum Alloy

Meshing is the task of partitioning a spatial domain into simple geometric elements such as triangles (in 2D) or tetrahedrons (in 3D). Meshes typically have to conform to boundaries. Furthermore, for many applications there are quality criteria that need to be met, such as ensuring that angles are not too small.

Gray Cast Iron 1.1512e+005 mm³ 0.82889 kg Cast Iron 1.1512e+005 mm³ 0.63732 kg Carbon Ceremic 1.1512e+005 mm³ 0.23025 kg Table 9: Mass & Volume VII. CONCLUSION      

Fig. 7: Meshing Statistics Nodes 32928 Elements 13910 Table 6:

REFERENCES

VI. ANALYSIS DETAILS A. Aluminum Alloy Object Name Max Min

Total Directional Deformation Deformation 1.9044e+005 -25.35 mm mm 1.9045e+005 -25.241 mm mm Table 6: Aluminum Alloy

Equivalent Stress 6.3551e-002 MPa 35.421 MPa

B. Cast Iron Object Name Max Min

Total Directional Deformation Deformation 1.9044e+005 -25.35 mm mm 1.9045e+005 -25.241 mm mm Table 7: Cast Iron

Equivalent Stress 6.3551e-002 MPa 35.421 MPa

C. Gray Cast Iron Object Name Max Min

Total Directional Deformation Deformation 1.2292e+005 -42.467 mm mm 1.2292e+005 -42.404 mm mm Table 8: Gray Cast Iron

Equivalent Stress 0.1427 MPa 34.569 MPa

D. Mass & Volume Materials

Properties Volume 1.1512e+005 mm³

As per our calculation and comparison we observe that Carbon ceramic disc brake is lighter than gray cast iron disc brake.

We have reduce approximate 75% weight by using carbon ceramic and its heat generation in disc plate.

The noise & vibration in braking will be low as compare to other convention brake material like cast iron, steel etc.

We observe that heat flux is more in cast iron during analysis and weight is also more.

Carbon Ceramic Brakes have many benefits over traditional cast iron brakes.

From 50% or more in unsprang-weight reduction to faster stopping distances.

Mass

[1] Er. N. B. Shinde and Prof. B.R. Borkar, “C.A.D. & F.E.M. ANALYSIS OF DISC BRAKE sysSYSTEM”, International Journal Of Engineering And Computer Science ,ISSN:2319-7242,Volume 4 Issue 3 March 2015, Page No. 10697-10706 [2] Manjunath T V and Dr Suresh P M,”Structural and Thermal Analysis of Rotor Disc of Disc Brake”, International Journal of Innovative Research in Science, Engineering and Technology, Vol. 2, Issue 12, December 2013 [3] Er. N. B. Shinde and Prof. B.R. Borkar,”Literature Review on Fem Analysis Of Disc Brake System” International Journal Of Engineering And Computer Science ISSN:2319-7242,Volume 4 Issue 2 February 2015, Page No. 10554-10558 [4] Vishal Asokan, Arshad Mohammed Gani,”Design And Analysis Of Reinforced Composite Matrix Disc Brake”, International Journal of Engineering Research and General Science Volume 3, Issue 5, SeptemberOctober, 2015,ISSN 2091-2730 [5] S.Sarip, “Design and Development of Disk Brake for Regenerative Braking- FEA”, International Journal for Applied Physics and Mathematics, Vol 3, No 1, January 2013 [6] Abdulwahab A. Alnaqi, “Optimization of Alumina coated Disk Brake Rotor”, SAE Technical Paper, 201401-2501,2014 [7] Vijay Parab and Prof. A.Dhale, “Structural and Thermal Analysis of Disk Brake”, IJEDR Vol 2 Issue 2.

[8] Abhishek Gaikwad and Deepak Singh, “Fabrication of Disk Brake for Regenerative Braking System”, Vol 4, Issue 5, May 2014 [9] Swapnil Abhang, D.P. Bhaskar, “Design and Analysis of Disk Brake”, IJETT, Vol 8, No 4, Feb 2014.

0.31889 kg

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