Jan 18, 2020 this cfd approach helped in the calculation of the values of the thermal coefficients h that have been exploited in the 3d transient evolution of the brake disc temperatures. The pad is made of a resinbonded composite friction material, and the disc is made of steel. Disc brake is usually made of cast iron, so it is being selected for investigating the effect of. Design and thermal analysis of disc brake rotor using. Number of times using the brake for vehicle leads to heat generation during braking event, such that disc brake undergoes breakage due to high temperature. Suresh, this paper deals with the analysis of disc brake. Introduction a disc brake is a type of brake that uses calipers to squeeze pairs of pads against a disc or rotor to create friction. The front brakes failed while the truck was hauling a trailer filled with cattle.
Braking system represents one of the most primary safety critical components in modern vehicles. The number of nodes used in this meshing is 43161 and elements are 28042. Thermal and structural analysis of disc brake assembly. Rameshkumar 1mechanical engineering department, karpagam college of engineering, coimbatore, india.
Here the disc brake is designed by using solidworks and analysis is done by ansys workbench r. The objective of this paper is to model and analyse stress concentration, structural deformation and thermal gradient of disc brake. Displacement and elemental stress analysis of brake pedal was done in hypermesh. The temperature distribution for vented disc at different time steps. Thermal analysis of a solid brake disc sciencedirect. Macuzic et al thermal analysis of solid and vented disc brake during the braking process c d fig. The design of brake rotor is done on solid works 15 and analysis is done with the help of ansys 14. Brake absorbs the kinetic energy of the rotating parts wheels and the energy is dissipated in the form of heat energy to the surrounding atmosphere. The disc has a thicker friction ring connected to a conical section that, in turn, connects to an inner hub. An attempt is made to analyse the brake disc using analytical as well. Transient thermal and structural analysis of the rotor disc. Transient thermal and structural analysis of the rotor disc of disk brake is aimed at evaluating the performance of disc brake rotor of a car under severe braking conditions and there by assist in disc rotor design and analysis. Step by step procedure of how to do steady state thermal analysis of a disc brake fsae in ansys workbench.
Design and thermal analysis of disc brake using ansys. How we measure reads a read is counted each time someone views a publication. The main purpose of this study is to analysis the thermomechanical behavior of the dry con tact of the brake disc during the braking phase. The aim of this paper is to realize the purpose of the holes in the disk brake. An investigation into usage of new materials is required which improve braking efficiency and provide. Structural and thermal analysis of brake drum anup kumar and r. Heat is generated due frictional contact between pad and disc. Pdf design and thermal analysis of disc brake using ansys creo. Disc brake model is done by catiaproe and analysis is done by using ansys. Thermal analysis on disc brakes rotor vipul h hingu, lecturer, mechanical department, sb polytechnic, kj campus savli abstract in this paper, authors present our results of thermal analysis of disc brake rotor used by twowheelers in india. The model using in ansys and done the thermal analysis and objective is to find out dimensions of rotor for given modal analysis also calculate the heat flux, temperature requirement and analyzing. The rotor discs are commonly manufactured of grey cast iron1.
Each single system of automotive along with brake system has come a long way in past years. How to ansys of a thermal analysis of disk brake youtube. Thermal analysis of rotor disc of disc brake of baja sae. Thermal analysis of solid and vented disc brake during the. The number of nodes used in this meshing is 95189 and elements are 65016.
The sae maintains a specification for the manufacture of grey iron for various applications2. Pdf structural and thermal analysis of rotor disc of. The transient thermal analysis of a disc brake is critical because the friction and braking performance decreases at high temperatures. The analysis was motivated by thermal cracking in the front disc brakes in a heavy duty ford f250 pickup truck. In this paper mathematical inputs, and thermal loads of brake rotor, calculations of different parameters required for thermal analysis is done by taking suitable assumptions. Thermo structural analysis of a brake disc youtube. Structural and thermal analysis of metal ceramic disk brake. An automotive disc brake is a device which creates resistance to the motion of wheel under running conditions. Transient thermal analysis of the rotor disc of disk brake is aimed at evaluating the performance of disc brake rotor of a car under severe braking conditions and there by assist in disc rotor. Thermal stress analysis of disc brake rotor by finite element. Thermal analysis of disc and heat flux distribution of disc was performed in ansys r16. Levicus john assistant professor mechanical department thermal cmr technical campus.
Structural and thermal analysis of metal ceramic disk brake mahammad rasul s. Here the disc brake is designed by using solidworks and analysis is done by ansys workbench r 14. The dimensions of the axisymmetric model are taken from a typical car disc brake. Most leading vehicle it ig manufacturers recommend brake disc skimming d. Fig 5 compares the sca rotor and the cast iron rotor with and without an aluminum wheel connected during repeated braking using the basic heat transfer equations. The disc brake two wheelers to design disc brakes for car and thermal analysis of rotor. Feb 07, 2016 thermal analysis of brake disc 2015 1. Introduction the disc brake is a wheel brake which slows rotation of the wheel by the friction caused by pushing brake pads against a brake disc with a set of calliper. A predictive tool to evaluate braking system performance. Thermal analysis of both ventilated and full disc brake rotors with. An investigation into usage of new materials is required which improve braking efficiency and provide greater stability to vehicle.
Disc brakes absorb the translational mechanical energy through friction and transform it into the thermal energy, which then dissipates. Meshing of the disc figure 5 shows the meshed model of disc brake for thermal analysis process. The brake drum is a critical component that experiences high temperatures and develop thermal. Structural and thermal analysis of rotor disc of disc brake. The latter is operated to visualize the disk temperature 3d.
Thermal and structural analysis of brake disc free download as powerpoint presentation. The steady state thermal analysis of two wheeler disc rotor aimed towards the evaluating the braking performance of two wheeler disc brake under braking condition. Highlights in this study, we presented a simulation of thermal behavior in the disc brake. We calculate the initial flux entering the disk to determine the coefficient h. Disc brake model and analysis is done using ansys workbench 14. During the braking phase, the frictional heat generated at the interface disc pads can lead to high temperatures. The experimental setup for the thermal analysis of brake disc consists of a bed on which an alternating current induction motor of 3 hp 3000rpm. The disc is allowed to reach the desired speed and the brake is applied by the help of brake lever. For the transient thermal analysis, second order elements are used for discretization of the disc and hub whereas cax6m second. The temperature resulting from this friction rises high. Disc brake is the recent trend in automobile vehicles which dissipates the heat faster than the conventional drum brakes. Pdf thermal analysis of a solid brake disc researchgate. Therefore, only half of the disc and one brake pad is modeled, and symmetry boundary conditions are applied.
This is important to understand action force and friction force on the disc brake new material, how disc brake works more. Thermomechanical analysis of automotive disc brake composite rotor. For analysis ventilated disc brake was messed using triangular surface mesher. Sabarish department of mechanical engineering, bharath university, chennai600 073, india abstract. This paper presents a failure analysis of thermal cracking in disc brake rotors. So, the model is meshed and then analysed to get the detail and correct result of the stress of the contact surface figure 5 thermal meshing of disc brake figure 6 structural meshing of disc brake. The thermal analysis of brakes is explained, including the calculation of temperatures reached in the brake components during braking, the effect of vehicle speed, load and deceleration, and the importance of sizing the foundation brakes to withstand thermal and mechanical loads. The work deals with the analysis of heat generation and dissipation in a solid disc brake of a motorcycle during continuous braking by using computeraided engineering software with two disc profile and three different materials of the rotor disc. Thermomechanical analysis of automotive disc brake composite. Thermo structural analysis of a brake disc vishal ganore. Keywords ansys, disc brake, braking system, fem, thermal analysis. Pdf braking is a process which converts the kinetic energy of the vehicle into mechanical energy which must be dissipated in the form of heat. The disc brake discs are commonly manufactured out of grey cast iron.
The disc brake is a device for slowing or stopping the rotation of a wheel. So a careful design and material selection is necessary to avoid the premature failure of the disc brake. The thermal analysis of the braking system requires a precise determination of the quantity of heat friction produced and as well as the distribution of this energy between the disc and the brake lining. A higher thermal conductivity means that the heat produced at the point of contact where the brake is engaged can be transmitted to the center of the brake more quickly, which results in better performance. The braking process was simulated in laboratory and the experimental data was used to verify the simulation results. When brakes are applied the temperature of the brake disc increases and is subjected to thermal stresses. During an emergency braking, all the heat produced with the interface is equal to the heat absorbed by the disc and the brake lining. Design and thermal analysis of disc brake rotor using aluminum alloy 2014 and generalized experimental analysis for temperature distribution d. Transient thermal and structural analysis of the rotor disc of disk brake is aimed at evaluating the performance of disc brake rotor of a car under severe braking conditions and there by assist in. The braking process was simulated in laboratory and the experimental data was used to. Structural analysis is done on the disc brake to validate the strength of the disc brake and thermal analysis is done to analyze the thermal properties.
Friction simulation on bicycle rim brake pad using ansys duration. In two wheeler brake system the material used for disc brake mostly is, alloy martensitic stainless steel and sometimes in high end bikes is carbon carbon. Keywords disc brake, thermal analysis, ansys introduction the disc brake is a wheel brake which slows the rotation of the wheel by the friction caused by pushing brake pads against a brake disc with a set of calipers as shown in fig. Rameshkumar 1mechanical engineering department, karpagam college of. Although this approach works well, it is not feasible due to extremely long computational times. The sae maintains a specification for the manufacture of grey iron for various applications. Introduction a brake is a device by way of which frictional resistance is found to shifting system member, in order to discontinue the motion of a system. It is then important to determine with precision, the temperature field and thermal stresses of the brake disc.
Particularly, for simulating repeated braking, this approach is of little importance for practical use. Jun 01, 20 step by step procedure of how to do steady state thermal analysis of a disc brake fsae in ansys workbench. This thermal analysis on brake discs is aimed to evaluate the performance of an electric car in the braking. The model using in ansys and done the thermal analysis and objective is to find out dimensions of rotor for given modal analysis also calculate the heat flux, temperature requirement and analyzing the results on ansys workbench. The basic function of disc brake is to stop or slow down the motion of wheel by applying frictional force through calliper assembly. Thermal and structural analysis of disc brake assembly during. The analysis led to aluminium metal matrix composite as the most appropriate material for brake disc system. Fe models of a disc brake system used in the modified axisymmetry analysis. The disc brake is a device used for slowing or stopping the rotation of the vehicle.
This paper deals with the theory behind thermal analysis of the brake, the method used to calculate the conversion of the cars kinetic energy to the brake s heat energy, to find the convection coefficient available due to the air flow on the car and to determine the overall temperature rise on the brake disc. Material selection method in design of automotive brake disc. Abstract the brake drum is a critical component that experiences high temperatures and develop thermal stresses during application of brakes. This paper aims to examine a transient thermal analysis of the disk rotor and pad contact problem for the disk brake system with frictional heat generation, and this simulation is performed by the. Modern vehicles have disc brakes on the front wheels, and there is. In addition, the application of shoe pressure gives rise to mechanical loads. Pdf thermal analysis of disc brake made of different. The previous figure visually shows that the vented disc is less heated than the solid disc. For normal car and light truck applications, the sae specifica tion is j431 g3000 superseded to g10. Braking system is one of the important safety components of.
Material of rotor disc of disc brake the rotor discs are commonly manufactured of grey cast iron1. Severe e keywords disc brake, thermal analysis, ansys ventilated discs only. Abstract transient thermal and structural analysis of the rotor disc of disk brake is aimed at evaluating the performance of disc brake rotor of a car under severe braking conditions and there by assist in disc rotor design and analysis. Disc brake model and analysis is done us ing ansys workbench 14. Therefore, we can optimize number of shapes of slot to estimate the good thermal conductivity of the disc brake rotor. Thermal analysis of disc brake using comsol haripal singh and harshdeep shergill department of mechanical engineering, rieit, ropar, p b india r ecieved 15 april 2012 accepted 30 april 2012 abstract. Pdf thermal analysis of disc brake made of different materials. Figure 4 values of heat transfer coefficient at the wall of disc brake 5. Design and thermal analysis of disc brake for minimizing. Pdf design and thermal analysis of disc brake using. This paper deals with thermal analysis through finite element analysis of rotor disc of disc brake of baja sae 20 car.
Three different brake disc materials were tested and comparative analysis of the results was conducted in order, to derive the one with the best thermal behavior. Figure 3 models the temperature flow in a disk brake 1. Repetitive braking of the vehicle leads to heat generation during each braking event. The thermomechanical properties for the axisymmetric model were taken from a paper by day and newcomb 1984 describing the analysis of an annular disc brake. Modern vehicles have disc brakes on the front wheels, and there is a developing fashion to. Thermal analysis of disc brakes using finite element. Braking is a process which converts the kinetic energy of the vehicle into mechanical energy which must be dissipated in the form of heat. Transient thermal and structural analysis of the rotor. Generally brake systems are designed to apply artificial frictional resistance to the rotating member in order to stop the rotational motion of a vehicle. The standard disc brake two wheelers model using in ansys and done the thermal analysis and modal analysis also calculate the deflection and heat flux, temperature of disc brake model. This work deals with the analysis of heat generation and dissipation in a disc brake of an car.
Pdf thermal analysis of disc brake using ansys researchgate. Brake disc rotor is an important component of disc brake assembly which is used to decelerate or stop the vehicle. Brake thermal analysis brake thermal analysis can be performed using the basic heat transfer equations, finite deference technique, and finite element method. Thermal stress analysis of automotive disc brakes by saiprasit koctniyom bsc eng, msc eng submitted in accordance with the requirements for the degree of doctor of philosophy the university of leeds school of mechanical engineering november 2000 the candidate confirms that the work submitted is his own and that appropriate credit. Thermal analysis of rotor disc of disc brake of baja sae 20. International journal of engineering trends and technology. Disc brake,rotor analysis, static analysis, thermal analysis, ansys. An attempt is made to analyse the brake disc using analytical as well as finite element analysis for its temperature as well as thermal stress distribution. Axisymmetric analysis of bolted disc brake assembly to. In this study, thermal stress analyses on a ventilated locomotive wheelmounted. Thermal analysis of locomotive wheelmounted brake disc. Valvano and lee 2000 simulated thermal analysis on a disc brake with a combination of computerbased thermal model and finiteelement febased techniques to provide a reliable method to calculate the temperature rise, thermal stress and distortion under a given brake schedule. Pdf irjet design and thermal analysis of disc brake.