Final Year Project Presentation (2)
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This project analyzed the thermal and mechanical loads on brake discs to understand deformation and cracking using computer aided design, simulation, and testing. The document outlines the project scope, prior research on brake disc analysis, experimental testing on a Vauxhall VX220 to measure heat rise under braking, validation of the mechanical clamping force and thermal stresses through calculations, finite element analysis of brake disc designs under thermal and mechanical loads, limitations, and suggestions for future work.
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STRUCTURAL AND THERMAL ANALYSIS OF DISC BRAKE USING SOLIDWORKS AND ANSYS
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.
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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.
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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.
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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.
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STRUCTURAL AND THERMAL ANALYSIS OF DISC BRAKE USING SOLIDWORKS AND ANSYS
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.
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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.
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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.
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During braking, friction between the disc and pad converts kinetic energy to heat energy, suddenly increasing the disc's temperature. Upon cooling, residual thermal stresses remain. Plastic deformation occurs due to thermal expansion/contraction, and after repeated braking cycles, cracks may initiate on the disc surface, leading to failure. The thesis uses finite element analysis to obtain the temperature profile and stresses in the disc under repeated braking to establish a basis for predicting low cycle fatigue life based on plastic strain amplitude.
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The document analyzes the thermal behavior of solid and ventilated disc brakes made from three materials - aluminum, grey cast iron, and structural steel - when subjected to braking forces through finite element analysis. Thermal simulations show that ventilated discs have better heat dissipation than solid discs, with maximum temperatures up to 8°F lower in ventilated models. Grey cast iron performed best overall with maximum temperatures under 150°F and was determined to meet strength and stability requirements for the application.
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This document summarizes a study that performed finite element analysis of the thermo-elastic behavior of disc brake rotors. The study analyzed the temperature distribution and stress patterns in three different materials for a disc brake rotor undergoing repeated braking conditions. The results validated that the transient thermal and structural analysis converged with the steady state solution over a 10 second braking period. The maximum temperatures achieved in the rotor and the conclusions drawn regarding the three materials are presented in the tables and figures.
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The current study essentially deals with the modeling and analyzing vented and non vented disc brake by CATIA and ANSYS. Finite element models of the brake disc are shaped with CATIA and simulated using ANSYS which is based on the finite element method. This study Structural analysis is done so as to get the strength of the disc brake. Here we discuss disc brake which is used in many vehicles. The stresses and variations developed in vented and non vented disc brakes are discussed using ANSYS software. Disc gets stressed when used in slowing down or stopping the vehicle. So that by using Ansys we can observe variations between stresses of vented and non vented disc brake. Disc brakes are mostly used on front wheels in two wheelers, hatchback cars and also widely used on both front and rear wheels of high end cars. The main aim of this paper is to minimize the Total deformation, Directional deformation, Equivalent stress and strain with best suited Material Analysis is done on both Vented and non vented disc brake. The Geometry of the models is carried out in the CATIA V5 R20 Software and is designed in Mechanical Design. The analysis part is done by using ANSYS R14.5 Software. Meesala Vanajakshi | Pothuraju. V. V. Satyanarayana | E. Lakshmi Devi "Static Structural Analysis of Vented and Non Vented Disc Brake" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-5 , August 2019, URL: https://www.ijtsrd.com/papers/ijtsrd26450.pdfPaper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/26450/static-structural-analysis-of-vented-and-non-vented-disc-brake/meesala-vanajakshi
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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.
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1) The document investigates the temperature and thermal stress in a ventilated disc brake system during braking using a 3D thermo-mechanical coupling model.
2) It builds a multi-body model of the ventilated brake disc and pad assembly that considers heat generation at the contact interface as well as convection heat transfer.
3) The model simulates the braking process from an initial speed of 100 kph down to 0 kph over 4.72 seconds, calculating the temperature field, thermal stress, and thermal distortion at each time step for validation against experimental data.
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International Journal of Computational Engineering Research (IJCER) is dedicated to protecting personal information and will make every reasonable effort to handle collected information appropriately. All information collected, as well as related requests, will be handled as carefully and efficiently as possible in accordance with IJCER standards for integrity and objectivity.
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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.
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1. The document presents a case study on stress analysis of a disc brake rotor in a static condition. It aims to optimize the design of a disc brake rotor for a 220cc Bajaj motorcycle.
2. The study models different slot shapes for the rotor in CATIA and analyzes them in ANSYS to determine stress levels, deformation, and performance under specified loads. It uses shape optimization techniques to find the design with minimum stress that maintains structural performance.
3. The results of the ANSYS analysis on the CAD models are presented, including equivalent stresses, total deformation, and force calculations. The optimal solution is identified by comparing results to existing commercially available rotors.
Coupled structual thermal analysis of disc brake
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
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Introduction : Simulation of thermal stresses in Disc Brakes
During braking, friction between the disc and pad converts kinetic energy to heat energy, suddenly increasing the disc's temperature. Upon cooling, residual thermal stresses remain. Plastic deformation occurs due to thermal expansion/contraction, and after repeated braking cycles, cracks may initiate on the disc surface, leading to failure. The thesis uses finite element analysis to obtain the temperature profile and stresses in the disc under repeated braking to establish a basis for predicting low cycle fatigue life based on plastic strain amplitude.
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The document analyzes the thermal behavior of solid and ventilated disc brakes made from three materials - aluminum, grey cast iron, and structural steel - when subjected to braking forces through finite element analysis. Thermal simulations show that ventilated discs have better heat dissipation than solid discs, with maximum temperatures up to 8°F lower in ventilated models. Grey cast iron performed best overall with maximum temperatures under 150°F and was determined to meet strength and stability requirements for the application.
Design and analysis of disc brake rotor for a two wheeler
This document summarizes a study that performed finite element analysis of the thermo-elastic behavior of disc brake rotors. The study analyzed the temperature distribution and stress patterns in three different materials for a disc brake rotor undergoing repeated braking conditions. The results validated that the transient thermal and structural analysis converged with the steady state solution over a 10 second braking period. The maximum temperatures achieved in the rotor and the conclusions drawn regarding the three materials are presented in the tables and figures.
Static Structural Analysis of Vented and Non Vented Disc Brake
The current study essentially deals with the modeling and analyzing vented and non vented disc brake by CATIA and ANSYS. Finite element models of the brake disc are shaped with CATIA and simulated using ANSYS which is based on the finite element method. This study Structural analysis is done so as to get the strength of the disc brake. Here we discuss disc brake which is used in many vehicles. The stresses and variations developed in vented and non vented disc brakes are discussed using ANSYS software. Disc gets stressed when used in slowing down or stopping the vehicle. So that by using Ansys we can observe variations between stresses of vented and non vented disc brake. Disc brakes are mostly used on front wheels in two wheelers, hatchback cars and also widely used on both front and rear wheels of high end cars. The main aim of this paper is to minimize the Total deformation, Directional deformation, Equivalent stress and strain with best suited Material Analysis is done on both Vented and non vented disc brake. The Geometry of the models is carried out in the CATIA V5 R20 Software and is designed in Mechanical Design. The analysis part is done by using ANSYS R14.5 Software. Meesala Vanajakshi | Pothuraju. V. V. Satyanarayana | E. Lakshmi Devi "Static Structural Analysis of Vented and Non Vented Disc Brake" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-5 , August 2019, URL: https://www.ijtsrd.com/papers/ijtsrd26450.pdfPaper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/26450/static-structural-analysis-of-vented-and-non-vented-disc-brake/meesala-vanajakshi
Structural analysis of a brake disc.pptm
This document summarizes a structural analysis of a brake disc conducted by students. They modeled a disc brake in ANSYS, applied appropriate loads and boundary conditions, and analyzed the results. Von Mises stresses were highest at the inner area where the shaft connects. Deflections and stresses obtained indicate the cast iron disc can withstand the applied pressure. The analysis can be improved by modifying the material or design, or adding ventilated areas to withstand thermal variations.
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The document discusses the analysis of brake drums using finite element modeling. It begins by stating that brake drums experience high thermal stresses from braking and need to withstand both thermal and mechanical loads. Finite element analysis is used to accurately model stress distribution since an analytical solution is not possible due to complex loading conditions. The analysis focuses on an internally expanding brake drum used in medium-duty vehicles.
DESIGN MODIFICATION OF DISC BRAKE AND PERFORMANCE ANALYSIS OF IT BY VARYING T...
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.
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This document summarizes a study that uses computational fluid dynamics (CFD) simulation to analyze the heat transfer coefficient of a brake rotor disc under different groove patterns. The study first outlines the analytical calculations for determining key brake design parameters like braking force, minimum disc size, required actuating force, and material selection. It then describes the CFD methodology used, including assumptions, modeling of the quarter disc, initial and boundary conditions applied. The results show that providing grooves improves the heat transfer coefficient near the grooves, and increasing the number of grooves enhances heat dissipation. The 24-groove pattern yielded the highest coefficient of 234 W/m2K. In conclusion, CFD insight helps understand the effect of
ADVANCED TRANSIENT THERMAL AND STRUCTURAL ANALYSIS OF DISC BRAKE BY USING ANS...
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.
Design and Thermal Analysis of Disc Brake for Minimizing Temperature
This document describes a study on the design and thermal analysis of disc brakes to minimize temperature. Different shapes and slot designs were modeled for a disc brake rotor using CATIA software and thermal analysis was performed using ANSYS. The results from static structural and transient thermal analysis for the original design and 5 new designs under various loading conditions are presented and compared. The analysis shows that the new design 5 performs the best with maximum stresses and temperature below the original design, indicating improved thermal conductivity and heat dissipation. This optimized design can help improve brake performance and safety.
Investigation of temperature and thermal stress in Disc Brakes
1) The document investigates the temperature and thermal stress in a ventilated disc brake system during braking using a 3D thermo-mechanical coupling model.
2) It builds a multi-body model of the ventilated brake disc and pad assembly that considers heat generation at the contact interface as well as convection heat transfer.
3) The model simulates the braking process from an initial speed of 100 kph down to 0 kph over 4.72 seconds, calculating the temperature field, thermal stress, and thermal distortion at each time step for validation against experimental data.
Design & Analysis of a Disc Brake using Fea
International Journal of Computational Engineering Research (IJCER) is dedicated to protecting personal information and will make every reasonable effort to handle collected information appropriately. All information collected, as well as related requests, will be handled as carefully and efficiently as possible in accordance with IJCER standards for integrity and objectivity.
Modeling and Thermal Analysis of Disc Brake
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.
Structural and Thermal Analysis of Metal - Ceramic Disk Brake
Disk brakes are using from so many years in automotive and still researches are going on in this field for decreasing the temperature effect so that by this we can operate easily. Many new materials are introduced for the disk brake rotor to withstand high temperature produced during braking action. Apart from the high temperature property, the disc rotor materials must also have high thermal conductivity property, as this property decides the amount of heat dissipation to the air stream from the disk rotor. A brake material with good temperature and high thermal conductivity property gives maximum efficiency by overcoming the problem of thermo-mechanical instability [TEI] in the rotor which is more common in low thermal conductivity brake rotor material. In the present work, a Grey cast iron material and metal-ceramic has been chosen for the disk brake rotor. Number of methods before already introduced to know the history of the different materials related to disk brakes, analysis will be done in 2d and 3d in analytical and numerical methods. With different types of assumptions these numerical methods ranges from finite differences to finite elements. To conclude the temperature history for the Grey cast iron material, and metal-ceramic, a numerical simulation technique called finite element method is used. Transient analysis is carried out in ANSYS to predict temperature distribution as a function of time in the disk brake rotor. The results from the transient analysis are compared. As the brake rotor can be treated as the coupled field problem, it is mandatory to do structural analysis after performing thermal analysis in ANSYS to study the stability and rigidity behavior of the rotor material. The results from the transient analysis are given as the input to the structural analysis in order to conclude the stress distribution and displacement in disk brake rotor under thermal loading. The stability behavior of different brake rotor material is compared to facilitate the conceptual design of the disk brake system.
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The document describes the optimization of brake disc geometry for a vehicle. It aims to minimize disc volume while meeting constraints on stress, natural frequency, and temperature during emergency braking. Finite element analysis is performed in ANSYS to analyze structural stress, vibration modes, and thermal loads. Design of experiments and response surface models are developed in MATLAB to optimize disc inner radius, outer radius, and thickness. Single-objective and multi-objective optimizations are conducted to determine optimal geometries under different load cases.
Experimental Analysis and Investigation for Thermal Behaviour of Ventilated D...
In the present review, we discuss works that have been published in the last 15 – 20 years that are based on the computational and experimental analysis of thermal properties of disc brake rotor of various types; new applications of the theory of heat conduction, convection and radiation. As the rapid development of computer engineering have led to a considerable increase in the number of solvable problems, and the refining of mathematical methods and approaches enables one to construct analytic solutions of these problems. In the paper, we outline the main directions of investigation of the processes of interaction of bodies with regard for heat release. We describe computational methods in more detail as compared with other approaches, because, to our mind, they are very promising for deriving simple engineering relations for braking processes on the basis of the equations of the thermal dynamics of friction; also the actual braking system is much transient and a lot of variable changes at a time which becomes very difficult to calculate experimentally.
Disc brake rotor analysis case study
1. The document presents a case study on stress analysis of a disc brake rotor in a static condition. It aims to optimize the design of a disc brake rotor for a 220cc Bajaj motorcycle.
2. The study models different slot shapes for the rotor in CATIA and analyzes them in ANSYS to determine stress levels, deformation, and performance under specified loads. It uses shape optimization techniques to find the design with minimum stress that maintains structural performance.
3. The results of the ANSYS analysis on the CAD models are presented, including equivalent stresses, total deformation, and force calculations. The optimal solution is identified by comparing results to existing commercially available rotors.
Coupled structual thermal analysis of disc brake
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Final Seminar
This document presents a dissertation on finite element modeling and analysis of brake squeal. It discusses how brake squeal is generated and analyzed using finite element methods. The objectives are to determine unstable squealing modes and frequencies of a brake system and analyze the effects of increased friction coefficient and disc diameter. The methodology involves building a finite element model of a disc-pad assembly in CATIA and performing modal and brake squeal analyses in ANSYS. Linear and nonlinear analyses are used to predict unstable frequencies with and without including prestress effects. The results of increasing parameters are also compared to experimental data.
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Introduction : Simulation of thermal stresses in Disc Brakes
Introduction : Simulation of thermal stresses in Disc Brakes
Design and analysis of disc brake rotor for a two wheeler
Design and analysis of disc brake rotor for a two wheeler
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DESIGN MODIFICATION OF DISC BRAKE AND PERFORMANCE ANALYSIS OF IT BY VARYING T...
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ADVANCED TRANSIENT THERMAL AND STRUCTURAL ANALYSIS OF DISC BRAKE BY USING ANS...
Design and Thermal Analysis of Disc Brake for Minimizing Temperature
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Investigation of temperature and thermal stress in Disc Brakes
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Structural and Thermal Analysis of Metal - Ceramic Disk Brake
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Experimental Analysis and Investigation for Thermal Behaviour of Ventilated D...
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- 1. Thermal Analysis Investigation of Brake Discs Using Creo Final Year Project Presentation Saqib Ahmed (B00238797) Supervisor – David Kennedy
- 2. Overview of Project This project touches upon the following modules – Computer Aided Design (CAD) Thermal and Mechanical Design Race Engineering Analysis & Simulation Design Prototyping and Testing Motorsport Design Engineering Application Project
- 3. Overview of Problem for Vauxhall VX220 Brake Disc Assumptions can be made, where the thermal and mechanical loads will cause the brake disc to deform/fatigue/crack.
- 4. Sources Regarding Project Author Title Year Overview Method Y. Yildiz, M. Duzgun Stress analysis of ventilated brake discs using the finite element method 2010 Stress Analysis of ventilated disc brakes via FEM, crack formations Experimental & Computational (Analytical) V.M.M Thilak, R Krishnaraj, M Sakthivel, K Kanthavel, Deepan Marudachalam, R Palani Transient thermal and structural analysis of the rotor disc of disc brake 2011 Transient Thermal Analysis via ANSYS Computational & Analytical Haripal Singh, Harshdeep Shergill Thermal Analysis of Disc Brake Using Comsol 2012 Analysis of heat dissipation/heat generation during emergency braking, comparison of three materials (conduction, convection & radiation) Computational & Analytical Ameer Fareed Basha Shaik, Ch. Lakshmi Srinivas STRUCTURAL AND THERMAL ANALYSIS OF DISC BRAKE WITH AND WITHOUT CROSSDRILLED ROTAR OF RACE CAR 2012 Thermal Analysis using ANSYS Computational & Analytical K. Sowjanya, S. Suresh Structural analysis of disc brake rotor 2013 Creo Parametric model of brake, using ANSYS for Von Mises stress, deflection and normal stresses Computational & Analytical Metropolitan Police Brake Test – 50mph to 0mph 50 times (http://www.fleetnews.co.uk/news/2004/11/2/fleet-in-focus-the-met/18004/)
- 5. Main Research • Modelling of Problem • Experiment • Mechanical/Thermal Loading Validation • FEA of Brake Disc Designs
- 6. Modelling of Problem Original VX220 Modified
- 7. Experiment on Vehicle (Heat Rise) FL FR Non-Contact ∆T (oC) Initial Temp 20.6 20.2 IR (oC) Before After Run 1 20.2 23.5 3.3 Run 2 25.9 30.3 4.4 Run 3 23.9 32.4 8.5 Ek = 1/2mv2 Ek = Q = mC∆T Since mC = constant, ∆T directly proportional to Ek Q = mC∆T ∆T = 8.5 ≈ 129171.8 J
- 8. Validation (Mechanical Clamp Force) Front Force Calculations Pad Contact Area (mm) 46.2 mm Effective Disc Rad (mm) 120.9 mm 0.1209 m Clamp Force, F 12688 N Per Side of Brake Disc 6343.8 N • Corner weights Calculated • 65-35 Front-Rear Brake Balance • Disc Dia – 288 mm Area 1 = 11145.5mm Area 2 = 14537.0mm Area of Webbing = 3391.5mm
- 9. Validation (Mechanical Clamp Force) 10% Leigh-way for FEA Stress found on model – 3.7744MPa Hand Calculations 𝑆𝑡𝑟𝑒𝑠𝑠 = 𝐹𝑜𝑟𝑐𝑒 𝐴𝑟𝑒𝑎 = 12688 3391.5 = 3.7MPa 𝑆𝑡𝑟𝑎𝑖𝑛 = 𝑆𝑡𝑟𝑒𝑠𝑠 𝑌𝑜𝑢𝑛𝑔′ 𝑠 𝑀𝑜𝑑𝑢𝑙𝑢𝑠 𝑆𝑡𝑟𝑎𝑖𝑛 = ∆𝐿 𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝐿𝑒𝑛𝑔𝑡ℎ
- 10. Validation (Thermal Stress Analysis) Cast iron 4.5% C, ASTM A-48 Yield Strength = 130MPa Ultimate Tensile Strength = 200 MPa Original VX220 Modified
- 11. Validation (Thermal Stress Analysis) Original MaxStress = 2738 MPa Realistic = 1643MPa VX220 MaxStress = 1212.18 MPa Realistic = 727.317 MPa Modified MaxStress = 1305.11MPa Realistic = 783.072 MPa
- 12. FE Analysis of Brake Discs Mechanical plus Thermal Load Cases Consider the bolt holes added to the model since this will allow the model to be free to rotate around in the z-axis Angular Velocity and Acceleration calculation required Consider the scaling of results (very important!)
- 13. Problems and Limitations of Project Working out exact values for the analysis Centre of Gravity of vehicle Exact calibration of the heat gun Limitations with CAD/FEA Software no underlying shells or beams in the mechanical & thermal analysis Fine details aborting analysis on Creo Simulate
- 14. Discussion & Conclusion Discussion To be completed - Timeline of Project Assumptions from Thermal & Mechanical Analysis Conclusion • Modelling of Problem • Experiment • Mechanical/Thermal Loading Validation • FEA of Brake Disc Designs
- 15. Future Research Choice of materials (isotopes) Centre of Gravity of Vehicle Experiment (knife-edge) Implementing dimensional analysis Using a different FEA software which is more suitable (Comsol, ANYSYS, ABAQUS CAE) More demanding physical test (Metropolitan Police) Physical modelling of modified brake design in controlled conditions Manufacturing methods and heat treatment to components
- 16. Thank you for listening! Any Questions?
Editor's Notes
- Hi my name is… 4th Year Project conducting it on the <title of project>
- Talk about the three designs (revolve, pattern etc) Original shitty design, prone to cracking The one found on the vehicle now, with slight part coming out Final design – front disc is straight
- Show pic of Vauxhall VX220 Talk about the speed (60.6 km/h) 3 runs taken Talk about apparatus (IR Non-Contact Heat Gun, Thermal Imager pic and talk about how the gun had to be calibrated) Talk about the relationship between the Ek, Q and delta T (equation) Results of this test – show table of the three runs Last one is the heat rise value that is taken; since heat is already generated in the components and heat flow shite blah blah blah
- Show screenshots of the three different brake disc designs Mention the constraint added to the model (hub hole surface, fixed in x,y and z axis Comparison, and validate against the overview of the problem