Mini bikes are normally preferred by for their light weight. Hence attention needs to be focused on
weight while configuring each and every key element like brake, gear box,engine, clutchs etc. Design
optimization of brake for one such mini brake has been taken up in this work. To start with, mathematical model
of the brake has been established so as to bring out the relation between key parameters of the design and the
same has been used in the later stage so as to formulate the optimization strategy. Configuring the brake by
choosing restraining value of width of brake lining in place of choosing restraining value of size of brake drum
yielded to reduction of volume and hence weight. Optimized design lead to increased area of lining which in
turn will reduce dissipation of energy per unit area. Accordingly it has bagged additional merits like reduction
in operating temperature and wear. Further a general purpose software has been developed using MATLAB for
design optimization of brake. For accomplishing this, formulation has been transformed in form of a code in
MATLAB. Programme has been written with interactive mode of operation which means upon executing the
programme it prompts the user to enter the value of inputs and subsequently it generates the outputs.
Modeling and Thermal Analysis of Disc BrakeIJERA Editor
The disc brake is a device used for slowing or stopping the rotation of the vehicle. 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. Disc brake model is done by CATIA and analysis is done by using ANSYS workbench. The main purpose of this project is to study the Thermal analysis of the Materials for the Aluminum, Grey Cast Iron, HSS M42, and HSS M2. A comparison between the four materials for the Thermal values and material properties obtained from the Thermal analysis low thermal gradient material is preferred. Hence best suitable design, low thermal gradient material Grey cast iron is preferred for the Disc Brakes for better performance.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
BRAKE DISC ANALYSIS WITH THE HELP OF ANSYS SOFTWAREIAEME Publication
There is lot of upgrade in the technology of the automobile these days. Competition on the speed of vehicles going on in the market. But also this speed leads to accidents if vehicle don’t stop on time. Disc brakes in the vehicles give much better performance compare to drum to stop the vehicle also the heat generated during braking force can be easily dissipated as disc brakes are open to atmosphere. But the main problem is with the material used in the disc brakes in some vehicle. Manufacturers use disc of steel which have short life span and the weight is bulky near the tire.
This Presentation shows the failure analysis of brake disc with help of case study of thermal fatigue cracks of fire fighting brake disc. It also include the component analysis of brake disc. The failure occurs due to the increase in temperature while applying hard braking.
Modeling and Thermal Analysis of Disc BrakeIJERA Editor
The disc brake is a device used for slowing or stopping the rotation of the vehicle. 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. Disc brake model is done by CATIA and analysis is done by using ANSYS workbench. The main purpose of this project is to study the Thermal analysis of the Materials for the Aluminum, Grey Cast Iron, HSS M42, and HSS M2. A comparison between the four materials for the Thermal values and material properties obtained from the Thermal analysis low thermal gradient material is preferred. Hence best suitable design, low thermal gradient material Grey cast iron is preferred for the Disc Brakes for better performance.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
BRAKE DISC ANALYSIS WITH THE HELP OF ANSYS SOFTWAREIAEME Publication
There is lot of upgrade in the technology of the automobile these days. Competition on the speed of vehicles going on in the market. But also this speed leads to accidents if vehicle don’t stop on time. Disc brakes in the vehicles give much better performance compare to drum to stop the vehicle also the heat generated during braking force can be easily dissipated as disc brakes are open to atmosphere. But the main problem is with the material used in the disc brakes in some vehicle. Manufacturers use disc of steel which have short life span and the weight is bulky near the tire.
This Presentation shows the failure analysis of brake disc with help of case study of thermal fatigue cracks of fire fighting brake disc. It also include the component analysis of brake disc. The failure occurs due to the increase in temperature while applying hard braking.
Thermo-Mechanical Analysis of Automotive Disc Brake Composite Rotorinventionjournals
The heat generated due to friction during braking operation causes several important negative effects on the brake system. It is then important to determine the temperature field of the brake disc. In the present work, a transient thermo-mechanical finite element analysis (FEA) is performed to determine the braking efficiency of a Carbon Ceramic disk brake and compared to a Glass Fiber (S-2) brakes. The aim of the work is to investigate the rise of the temperature of the disk brake under severe braking conditions and the stresses generated from it. The investigation will be done using ANSYS software. ANSYS is a powerful FE package used to determine stress, strain and heat transfer in complicated problems
Thermal and Structural Analysis Using Fea on Pillar Vains Type Ventilated Dis...IJSRD
Safety aspect in automotive engineering has been considered as a number one priority in development of new vehicle. Each single system has been studied and developed in order to meet safety requirement. Instead of having good suspension systems, Air bags, good handling and safe cornering, there is one most critical system in the vehicle which is brake systems. Without brake system in the vehicle will put a passenger in unsafe position. Therefore, it is must for all vehicles to have proper brake system. For the purpose of safety and increased life cycle of the disc brakes this paper deals with the design modification of a disc break so as to produce better thermal and structural performance.
ADVANCED TRANSIENT THERMAL AND STRUCTURAL ANALYSIS OF DISC BRAKE BY USING ANS...ijiert bestjournal
In these paper structural fields of the solid disc brake during short and emergency braking with four different materials is studied. The distribution of the tempe rature depends on the various factors such as frict ion,surface roughness and speed. The effect of the angular velo city and the contact pressure induces the temperatu re rise of disc brake. The finite element simulation for three -dimensional model was preferred due to the heat fl ux ratio constantly distributed in circumferential direction . Here value of temperature,friction contact power,nodal displacement and deformation for different pressure condition using analysis software with four materi als namely cast iron,cast steel,aluminium and carbon fibre reinforced plastic are taken. Presently the D isc brakes are made up of cast iron and cast steel. With the v alue of simulation result best suitable material fo r the brake drum with higher life span is determined.
THERMAL & STRUCTURAL ANALYSIS ON DISC BRAKE ROTOR WITH DRAFTING USING CATIA ...NitinSuryawanshi12
Project consist of two types of analysis thermal , structural & VBA Programming.
Thermal analysis is done to check the thermal resistance of model Honda Unicorn 160.
Structural analysis is done to find the strength of the model.
VBA programming is used to automate drafting task.
STRUCTURAL AND THERMAL ANALYSIS OF DISC BRAKE USING SOLIDWORKS AND ANSYSIAEME Publication
Braking system represents one of the most fundamental safety critical components in modern vehicles. Brake absorbs kinetic energy of the rotating parts (Wheels) and the energy is dissipated in the form of heat energy to the surrounding atmosphere. It decelerates or stops the vehicle. When brake is applied to the disc brake it is subjected to high stress, thus it may suffer structural and wear issues. Hence for the better performance, structural, stress and the thermal analysis is preferred to choose low stress material.
SELECTION OF THE DISC BRAKE MATERIAL USING PIN ON DISC APPARATUSijiert bestjournal
An automobil e brake disc is a device used for slowing or stopping the motion of a wheel while it runs at certain speed. The mostly used brake disc material is cast iron which consumes much fuel due to high specific gravity. The main aim is to develop the material selection and select optimum material for the application of brake disc system for better working. Th e paper describes the tribological behavior of the conventional materials i.e . Gray cast Iron,Structural steel,Aluminum and High speed steel (HSS) . In this paper to check major tri biological parameters for these four materials and try to suggest better new material compared to conventional existing material. After Test on wear machine we f ind the best suitable material for disc brake applications because of its low wear rate,low frictional force,low coefficient of friction,low cost,better mechanical properties than o ther.
FEA based Dissipation Energy and Temperature Distribution of Rubber BushingIJERA Editor
Rubber bushings used in the vehicle or aerospace can reduce the noise and vibration and absorb the shocks. The
heat accumulation in the rubber components is attributed to the nonlinear mechanical behavior of rubber and
leads to degeneration of mechanical properties. The viscoelastic damping is treated as the major mechanism of
dissipation energy, which is heat source of temperature rising in bushing. A finite element method is expanded
from elastic structure to viscoelastic structure and computes the dissipation energy distribution in the rubber
core. Based on that heat source, the temperature distribution of rubber bushing under radial harmonic excitation
has been calculated using finite volume method. The frequency and amplitude effect on dissipation energy and
temperature distribution are described. The radial dynamic testing is carried out and the temperature is recorded
using thermal imager to evaluate the simulation. As complement, the dynamic torsional testing is also carried
out explore the possible failure zone of rubber bushing under different types of loading.
Thermo-Mechanical Analysis of Automotive Disc Brake Composite Rotorinventionjournals
The heat generated due to friction during braking operation causes several important negative effects on the brake system. It is then important to determine the temperature field of the brake disc. In the present work, a transient thermo-mechanical finite element analysis (FEA) is performed to determine the braking efficiency of a Carbon Ceramic disk brake and compared to a Glass Fiber (S-2) brakes. The aim of the work is to investigate the rise of the temperature of the disk brake under severe braking conditions and the stresses generated from it. The investigation will be done using ANSYS software. ANSYS is a powerful FE package used to determine stress, strain and heat transfer in complicated problems
Thermal and Structural Analysis Using Fea on Pillar Vains Type Ventilated Dis...IJSRD
Safety aspect in automotive engineering has been considered as a number one priority in development of new vehicle. Each single system has been studied and developed in order to meet safety requirement. Instead of having good suspension systems, Air bags, good handling and safe cornering, there is one most critical system in the vehicle which is brake systems. Without brake system in the vehicle will put a passenger in unsafe position. Therefore, it is must for all vehicles to have proper brake system. For the purpose of safety and increased life cycle of the disc brakes this paper deals with the design modification of a disc break so as to produce better thermal and structural performance.
ADVANCED TRANSIENT THERMAL AND STRUCTURAL ANALYSIS OF DISC BRAKE BY USING ANS...ijiert bestjournal
In these paper structural fields of the solid disc brake during short and emergency braking with four different materials is studied. The distribution of the tempe rature depends on the various factors such as frict ion,surface roughness and speed. The effect of the angular velo city and the contact pressure induces the temperatu re rise of disc brake. The finite element simulation for three -dimensional model was preferred due to the heat fl ux ratio constantly distributed in circumferential direction . Here value of temperature,friction contact power,nodal displacement and deformation for different pressure condition using analysis software with four materi als namely cast iron,cast steel,aluminium and carbon fibre reinforced plastic are taken. Presently the D isc brakes are made up of cast iron and cast steel. With the v alue of simulation result best suitable material fo r the brake drum with higher life span is determined.
THERMAL & STRUCTURAL ANALYSIS ON DISC BRAKE ROTOR WITH DRAFTING USING CATIA ...NitinSuryawanshi12
Project consist of two types of analysis thermal , structural & VBA Programming.
Thermal analysis is done to check the thermal resistance of model Honda Unicorn 160.
Structural analysis is done to find the strength of the model.
VBA programming is used to automate drafting task.
STRUCTURAL AND THERMAL ANALYSIS OF DISC BRAKE USING SOLIDWORKS AND ANSYSIAEME Publication
Braking system represents one of the most fundamental safety critical components in modern vehicles. Brake absorbs kinetic energy of the rotating parts (Wheels) and the energy is dissipated in the form of heat energy to the surrounding atmosphere. It decelerates or stops the vehicle. When brake is applied to the disc brake it is subjected to high stress, thus it may suffer structural and wear issues. Hence for the better performance, structural, stress and the thermal analysis is preferred to choose low stress material.
SELECTION OF THE DISC BRAKE MATERIAL USING PIN ON DISC APPARATUSijiert bestjournal
An automobil e brake disc is a device used for slowing or stopping the motion of a wheel while it runs at certain speed. The mostly used brake disc material is cast iron which consumes much fuel due to high specific gravity. The main aim is to develop the material selection and select optimum material for the application of brake disc system for better working. Th e paper describes the tribological behavior of the conventional materials i.e . Gray cast Iron,Structural steel,Aluminum and High speed steel (HSS) . In this paper to check major tri biological parameters for these four materials and try to suggest better new material compared to conventional existing material. After Test on wear machine we f ind the best suitable material for disc brake applications because of its low wear rate,low frictional force,low coefficient of friction,low cost,better mechanical properties than o ther.
FEA based Dissipation Energy and Temperature Distribution of Rubber BushingIJERA Editor
Rubber bushings used in the vehicle or aerospace can reduce the noise and vibration and absorb the shocks. The
heat accumulation in the rubber components is attributed to the nonlinear mechanical behavior of rubber and
leads to degeneration of mechanical properties. The viscoelastic damping is treated as the major mechanism of
dissipation energy, which is heat source of temperature rising in bushing. A finite element method is expanded
from elastic structure to viscoelastic structure and computes the dissipation energy distribution in the rubber
core. Based on that heat source, the temperature distribution of rubber bushing under radial harmonic excitation
has been calculated using finite volume method. The frequency and amplitude effect on dissipation energy and
temperature distribution are described. The radial dynamic testing is carried out and the temperature is recorded
using thermal imager to evaluate the simulation. As complement, the dynamic torsional testing is also carried
out explore the possible failure zone of rubber bushing under different types of loading.
Cast iron is extensively used as the material for manufacturing disc brakes. This is much heavier and thus reduces initial acceleration and causes more fuel consumption. For reducing these effects, we use ceramic brakes.
In this paper three different cut patterns of brake disc are studied for heat transfer rate. Heat transfer rate increases with number of cuts in the disc. This is because large area is exposed to air which makes more heat transfer through conduction and convection. But increase in number and size of cuts decreases the strength of disc. And analysed thermally in ANSYS for different material and design created in CREO 3.0.
DESIGN MODIFICATION OF DISC BRAKE AND PERFORMANCE ANALYSIS OF IT BY VARYING T...ijsrd.com
Automobile braking system is one of the most important mechanical devices among the others. The disc brake is a device that slows or stops the rotation of a wheel by converting the friction to heat. But if the brakes get too hot, they will cease to work as they cannot dissipate enough heat. This condition of failure is known as brake fade. Disc brakes are exposed to large thermal stresses during routine braking and extraordinary thermal stresses during hard braking. Ventilation applications on disc brake can significantly improve the brake system performance by reducing the heating of the discs. In this study, the thermal behavior as well as the performance of ventilated brake discs using different pattern of holes will be investigated at continuous brake conditions with finite element analysis and the results will be compared with a solid disc.
A Review Design of Effective Braking and Efficient Transmission Systemijtsrd
This paper focuses on the designing, simulation and fabrication of brake disc and a constant speed two stage reduction gearbox for an All Terrain Vehicle ATV . In our paper, we have presented an efficient gearbox and brake disc which is lightweight and long lasting. The drive train consists of Continuous Variable Transmission CVT and a constant mesh two stage reduction gearbox. The gearbox and disc brake were modeled on SOLIDWORKS version 2018 and analyzed on ANSYS mechanical workbench version 2016 and the result were found to be satisfactory. Shashwat Kulshreshtha | Shantanu Tiwari | Naman Varshney | Shikhar Verma | Mayank Kushwaha "A Review: Design of Effective Braking and Efficient Transmission System" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-4 | Issue-4 , June 2020, URL: https://www.ijtsrd.com/papers/ijtsrd30969.pdf Paper Url :https://www.ijtsrd.com/engineering/mechanical-engineering/30969/a-review-design-of-effective-braking-and-efficient-transmission-system/shashwat-kulshreshtha
Design and analysis of an electric karteSAT Journals
Abstract This paper presents the design and analysis of an electric motor powered kart. The main aim of this paper is to reduce the usage of organic fuel powered vehicles and to design a vehicle which works efficiently in the emerging electric vehicle sector. In order to maintain the speed levels of the kart, seamless decision was made in motor selection. Alternate materials have been applied in the kart to reduce both static and dynamic forces in pursuance of improving the efficiency and performance of the kart. Detailed design of subsystems like chassis frame, steering system, electrical power train and braking mechanism has been done effectively. The main focus of the frame design was on the stability of the kart and safety of the driver. The CAD model of the kart was done in CREO 2.0. Aluminium alloy 6063 has been employed for the frame to reduce the overall weight. To check the feasibility of the frame design, finite element analysis has been done using ANSYS 14.5. The results obtained showed that the frame design was safe under maximal impact load conditions. Weight reduction was a major concern and hence linkage type steering was selected for the kart. Motor, the heart of the electric vehicle was selected and installed in such a way that it can perform well for an extended run time. PMDC motor was selected in this case. Speed control of the kart was done using a voltage controller. The kart is provided with a timing belt drive to achieve maximum efficiency in transmission of power from the motor to the wheels. Hydraulic disc brakes were provided for smooth and effective braking under both dry and wet conditions. Slick tires are used to provide more traction. Design calculations were carried out and optimum results were obtained. An extensive market survey was also done on frame material, brakes, motor, transmission system for cost and availability. International standards were followed throughout the design process. Keywords: Stability, Frame, Finite Element Analysis, PMDC Motor, Timing belt
collision. There are number of wheel test are available in designing of rim to fulfill the safety requirements
and standards. The aim of this study was to analyze and study the structure for car wheel rim by using the
numerical method. The most of the test procedure has to comply with international standards, which establishes
minimum mechanical requirements and impact collision characteristics of wheels. Numerical implementation of
impact test is convenient for shorten the design time and lower development cost. In this study cast aluminium
alloy wheel rim are used for simulation of impact test by using 3–D explicit finite element methods. The design
of aluminium alloy wheel for automobile application which is carried out and paying special attention to
optimization of the shape and mass of the wheel rim according to aesthetical point of view, to overcome the
wheel cap. A finite element model of the wheel with its tire and striker were developed taking account of the
nonlinearity material properties. Simulation was conducted to study the stress and displacement distributions
during impact test. The analyses results are presented as a function of time. The study is carried under the above
constraints and the results are taken to carryout for further analysis i.e. shape and weight optimization of the
wheel.
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Quality defects in TMT Bars, Possible causes and Potential Solutions.PrashantGoswami42
Maintaining high-quality standards in the production of TMT bars is crucial for ensuring structural integrity in construction. Addressing common defects through careful monitoring, standardized processes, and advanced technology can significantly improve the quality of TMT bars. Continuous training and adherence to quality control measures will also play a pivotal role in minimizing these defects.
Development of Software Using Matlab for Design Optimization of Brake for Minibike
1. IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE)
e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 12, Issue 6 Ver.III (Nov. - Dec. 2015), PP 24-29
www.iosrjournals.org
DOI: 10.9790/1684-12632429 www.iosrjournals.org 24 | Page
Development of Software Using Matlab for Design Optimization
of Brake for Minibike
Anil Kumar Garikapati1
, Dr. N. Govind2
, Dr.RavindraKommineni3
,V.Anand
Kumar4
1
Associate Professor, Department of Mechanical Engineering, Tirumala College of Engineering, Narasaraopet,
522601,
2
Associate Professor, Department of Mechanical Engineering, RVRJC College of Engineering, Guntur,522019,
3
Professor&HOD, Department of Mechanical Engineering, RVRJC College of Engineering,Guntur,5220019
4
Assistant Professor, Department of Mechanical Engineering,VNR Vignana Jyothi Institute of Engineering and
Technology, Hyderabad..
Abstract: Mini bikes are normally preferred by for their light weight. Hence attention needs to be focused on
weight while configuring each and every key element like brake, gear box,engine, clutchs etc. Design
optimization of brake for one such mini brake has been taken up in this work. To start with, mathematical model
of the brake has been established so as to bring out the relation between key parameters of the design and the
same has been used in the later stage so as to formulate the optimization strategy. Configuring the brake by
choosing restraining value of width of brake lining in place of choosing restraining value of size of brake drum
yielded to reduction of volume and hence weight. Optimized design lead to increased area of lining which in
turn will reduce dissipation of energy per unit area. Accordingly it has bagged additional merits like reduction
in operating temperature and wear. Further a general purpose software has been developed using MATLAB for
design optimization of brake. For accomplishing this, formulation has been transformed in form of a code in
MATLAB. Programme has been written with interactive mode of operation which means upon executing the
programme it prompts the user to enter the value of inputs and subsequently it generates the outputs.
Keywords: Optimization, Mathematical modelling, Brake lining, MATLAB, etc .
I. Introduction
Light weight vehicles like mini bikes need to be configured while giving utmost attention to key
elements like brake, clutch, gears, etc in optimal manner. Mathematical modeling of the intended subsystem
needs to be established before making an attempt for optimization. Relation between various design parameters
need to be understood so as to carry out optimization effectively. Primary objective of the optimization would
be reduction of volume and hence weight. Design optimization of brake meant for one such mini bike is
considered in this project. One such typical brake of a mini bike is shown in Fig. 1.
Fig. 1. Typical brake of a mini bike
To begin with efforts have been put up to understand the state of art for design optimization procedure
that needs to be applied for the planned requirement.
Each and every system has been studied and developed so as to meet safety. In place of having air bag,
apt suspension systems, good handling and safe surrounding, there is one another critical system in the vehicle
which is nothing but brake systems. Without proper brake system, vehicle will put a passenger in risk.
2. Development of Software Using Matlab for Design Optimization of Brake for Minibike
DOI: 10.9790/1684-12632429 www.iosrjournals.org 25 | Page
Therefore, it is must for all vehicles to have suitable brake system. In this work carbon ceramic matrix disc
brake material used for estimating normal force, shear force and piston force. The typical disc brake has been
modeled in ANSYS and thermal analysis and modal analysis were done and the deflection, heat flux,
temperature of disc brake are calculated. This is essential to know how disc brake works more effectively, which
can assist to reduce the hazard that may happen any time [1]. The objective of this paper is to optimize the
design of brake drum by reverse engineering approach. Optimization is carried out by altering the material of
the brake drum, under various braking time and operational situations. Brake drum is optimized and evaluated
different stresses, displacement values, increase in temperature on various braking instances and heat transfer
rate. Optimized results thus obtained are compared for aluminium and controlled expansion material alloys. It
completes that the controlled expansion alloys can be a right candidate material for the brake drum installations
of light commercial vehicles and it also enhances the braking performance [2]. Disc brake consists of a cast iron
disc attached to the wheel hub with bolt and a fixed housing called caliper. The caliper is attached to some fixed
part of the vehicle like the axle casing or the stub axle as it is cast in two different parts out of which each part
consists of a piston. Between each piston and the disc there exists a friction pad held in place by retaining pins,
spring plates. The passages are so attached to another one for bleeding. Each cylinder consists of rubber sealing
ring between the cylinder and piston. Due to the usage of brakes on the disc brake rotor, heat generates due to
friction and this temperature so produced has to be dissipated across the disc rotor cross section. The objective
of this paper is to study the temperature and also structural characteristics of the solid disc brake during short
and emergency braking with four dissimilar materials. The temperature distribution depends on different factors
such as friction, material and speed. The effect of the angular velocity and the contact pressure creates the
temperature rise of disc brake. The finite element analysis for two-dimensional model is considered due to the
heat flux ratio uniformly distributed in circumferential direction. Currently the disc brakes are made up of cast
iron and cast steel. With the value at the hand the best suitable material for the brake drum can be determined
with maximum life span. The detailed drawings of all subsystems are provided [3]. An automobile brake disc or
rotor is a device for retarding the motion of a wheel while it runs at a certain speed. Mostly used brake rotor
material is cast iron which spends much fuel due to its high specific gravity. The objective of this paper is to
develop the material selection methodology and choose the best material for the application of brake disc system
highlighting on the substitution of this cast iron by any other lighter material. Two methods are discussed for the
selection of materials. Material performance requirements were studied and alternative solutions are evolved
among cast iron, aluminium alloy, titanium alloy, ceramics and composites. Mechanical properties including
compressive strength, friction coefficient, wear resistance, thermal conductivity and specific gravity as well as
cost, are used as the chief parameters in the material selection stages. The analysis yielded to aluminium metal
matrix composite as the most correct material for brake disc system [4]. Brake lining material is an improper
conductor of heat; most of the heat passes into the disc during braking. Under simple use, brake disc may reach
high temperatures. The coefficient of friction between the disc and lining is condensed excessively at these high
temperatures, so that extra pedal pressure is required. So as to reduce the brake fade operation the design of disc
should be in such a way that the heat generated during braking should be easily carried away to the atmosphere
so that brake fade operation will not occur. Also optimization of weight can decrease the manufacturing cost
along with the sluggishness effect of the disc [5]. In this analysis, a new wedge disc brake performance is
evaluated using brake dynamometer and Taguchi method. The Taguchi method is frequently used in the
industry for optimizing the product and the process conditions. Taguchi orthogonal design method is used to
increase better understanding about the factors that effect of wedge brake enactment using L9 orthogonal array.
Three control factors were reflected as applied pressure, vehicle speed and wedge angle inclination, each at
three levels is chosen. It can be concluded that Taguchi method is trustworthy and decrease the time and
experimental costs. In addition, the results shown that the applied pressure and wedge angle are the most
noteworthy parameters for evaluation of the wedge disc brake [6].
As can be seen, optimization techniques are not so effective and practical implementation of the same
would be tedious. Under these circumstances great need exists for design optimization of brake with following
merits.
Reduction of volume and hence weight
Increased area of lining
Reduction in dissipation of energy per unit area
II. Design Inputs
Coefficient of friction for brake = 0.4
Size of drum = 200 mm
Allowable stress = 100 MPa
Maximum pressure rating of brake = 0.23 MPa
Torque = 40000 N-mm
3. Development of Software Using Matlab for Design Optimization of Brake for Minibike
DOI: 10.9790/1684-12632429 www.iosrjournals.org 26 | Page
III. Design Constraints
Size of drum < 200 mm
Width of brake lining < 25 mm
Wrap angle < 2900
Factor of safety (FOS) > 1.5
IV. Mathematical Modeling
Design parameters are shown in Fig. 2.
Fig. 2. Design parameters
Where
ω: Angular velocity
α: Wrap angle
r: Outer radius of brake drum
F1, F2: Forces acting on either side of brake band
Taking equilibrium of forces acting on parallel and orthogonal directions to that of tangent to a small element of
brake at its center yields to
(1)0
2
cos
2
cos
pwrd
d
F
d
dFF
(2)0
2
sin
2
sin
pwrd
d
F
d
dFF
Where
µ: Coefficient of friction for brake
p: Pressure acting on lining
w: Width of brake lining
1
2
osand
22
in0,d
d
c
dd
sAs
And
Fdtocomparednegligiblebecomes
2
F
d
d
With all above
Equation (1) reduces to
dF = µ.p.w.r.d (3)
Further equation (2) reduces to
F = p.w.r (4)
Substituting equation (4) in equation (3) and integrating gives
ddF
F
1
02
ln
F
FF
4. Development of Software Using Matlab for Design Optimization of Brake for Minibike
DOI: 10.9790/1684-12632429 www.iosrjournals.org 27 | Page
ln F – ln F2 = µ. (5)
µln 2F
F
(6)
µ
2F
F
e
Which represents tangential force in the brake as a function of position along the brake
Thenhen 1FFW
With which equation (6) becomes
(7)µ
2F
1F
e
Equation (7) conveys that when approaches α force attains its maximum value i.e. F1
Considering this, equation (4) can be rewritten as
F1 = pmax.w.r (8)
Equation 8 highlights the disadvantage of the brake that wear of the lining is more at high pressure side of
the brake. Due to this the lining should be swapped when it is worn out at only one side, or it has to be swapped
near around mid of its life or brake should have more lining materials with different friction coefficients so as to
avoid replacement of lining very often.
Further relation between torque applied by the brake and force can be expressed as
T = (F1-F2) r (9)
Substituting equations (7) and (8) in(9) yields
T = pmax. w.r2
(1-e-µα
) (10)
Equation (10) relates maximum constraining torque of the brake with its dimensions and its maximum pressure
(Compressive)
V. Existing Design
Width of brake lining for the existing design has been calculated from equation (10) as follows
(11)μαe12rmaxp
Tw
From this expression w = 20 mm
Area of brake lining can be expressed as
A = α.r.w (12)
From this expression A = 10142 mm2
Factor of safety can be expressed as
From this expression working stress = 66.67 MPa
Working stress can also be expressed as
From equation (4)
F =460.8 N
d1: Size of link
Substitution of necessary inputs gives d1= 3 mm
VI. Design Optimization
Width of brake lining for the existing design is 20 mm as calculated using equation (11). However its
restraining value imposed by space constraints is 25 mm. It is decided to explore the advantage of utilizing the
(13)
stressWorking
stressAllowable
FOS
(14)
2
14
F
linkofArea
Force
stressWorking
d
5. Development of Software Using Matlab for Design Optimization of Brake for Minibike
DOI: 10.9790/1684-12632429 www.iosrjournals.org 28 | Page
width of lining to the fullest extent permitted so as to optimize the existing design. Accordingly size of drum has
been reworked taking the restraining value of width of lining i.e. 25 mm as follows.
Equation (10) can be rearranged as
(15)
μαe1w
max
p
Tr
From this expression r = 90 mm
From which size of drum (D) = 2 x r = 180 mm
From equation (12)
Area of brake lining, A = 11328 mm2
From equation (14)
Size of link d1 = 3.1 mm
VII. Results And Discussion
Parameters for optimized design are compared with that of existing one in table 1.
Table 1. Summary of design parameters
Sl.
No.
Parameter Existing design Optimized
design
1. Size of drum 200 mm 180 mm
2. Width of lining 20 mm 25 mm
3. Area of lining 10142 mm2
11328 mm2
4. Size of link 3 mm 3.1 mm
5. Torque 40000 N-mm
6. Pressure 0.23 MPa
Both the configurations meets the design constraints
But for the same torque and pressure capability of brake lining optimized design yields to lesser drum
size which contributes a lot to both volume and weight.
Further brake having higher lining area dissipates less energy per unit area which imparts two high
order merits to the design which are: Lower operating temperature and less wear of lining
VIII. Development Of Software In Matlab
General purpose software has been developed using MATLAB for design optimization of brake. For
accomplishing this formulation stated in section (5) has been transformed in to some form of a code in
MATLAB and the screen shot of associated m-file is shown in Fig. 3.
Fig. 3. Screen shot of associated m-file
6. Development of Software Using Matlab for Design Optimization of Brake for Minibike
DOI: 10.9790/1684-12632429 www.iosrjournals.org 29 | Page
Programme has been written with interactive mode of operation which means upon executing the
programme it prompts the user to enter the value of inputs as shown in Fig. 4.
Fig. 4. Inputs needed to execute the code
Subsequently programme will generate the outputs as shown in Fig. 5.
Fig. 5. Outputs generated by the code
IX. Conclusions
Reconfiguring the design of brake for mini bike by choosing the restraining value of lining width rather
than choosing restraining value of size of drum yielded to reduction in volume and weight and hence resulted in
optimizing the design. It also reduced the operating temperature and wear.
Acknowledgement
This research is supported by Science and Engineering Research Council (SERC), Department of
Science and Technology (DST) New Delhi, INDIA. (SR/SR3/MERC-098/2007)
References
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