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SIMULATION OF
THERMAL STRESSES
IN A DISC BRAKE
MADE BY
AYUSH DEWANGAN
B.VENKAT SWAROOP
HARISH CHANDRA
GUIDED BY
MR.CHANDRA SHEKHAR
SAHU
( Asst.Profesor )
MECHANICAL DEPT.
The heat flux produced from the friction between a disc and pad
system leads to a high temperature which causes thermal stresses in
the disc and after a number of repeated braking cycles, cracks might
be initiated. The finite element analysis (FEA) is performed to
determine the temperatures profile in the disc and to analyze the
stresses for the repeated braking, which could be used to calculate the
fatigue life of a disc.
THESIS WORK 2012
PRODUCT DEVELOPMENT AND MATERIALS
ENGINEERING
This thesis work has been carried out at the School of Engineering in
Jönköping in the subject area Product Development and Materials Engineering.
The work is a part of the master’s degree. The authors take full responsibility for
the given opinions, conclusions and findings.
MADE BY- ASNAF AZIZ AND JIYUE TAO
During braking, the kinetic energy of the moving vehicle
is converted into heat energy due to friction between disc
and pad. As a result the temperature of the disc in contact
with the pad is suddenly increased. Upon cooling the heat is
dissipated by convection and radiation leaving some
residual thermal stresses.
Plastic deformation occurs due to large thermal
expansion/contraction. After repeated number of braking
cycles, cracks might be initiated on the disc surface which
leads to failure.
Theoretical background for plasticity, flow rules and
hardening models is presented in very detail manner. The
work on the heat analysis and thermo-mechanical
contact problem is also studied.
OBJECTIVE
The thermo-mechanical contact problem is divided into
two parts for analysis, heat problem and stress problem. The
finite element method is used to obtain the temperature, thermal
stresses and strains for the disc-pad system. To investigate the
elastic-plastic thermal stress analysis for a brake disc under
cyclic temperature gradients, the plasticity theory and flow rules
are discussed. Proper consideration is also given to the material
hardening models. In this thesis, the disc-pad system is studied
only for few repeated braking cycles so that to establish the
background for predicting the low cycle fatigue life (based on
plastic strain amplitude) of the disc brake, which is the ultimate
objective of this whole project.
THANK YOU

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Introduction : Simulation of thermal stresses in Disc Brakes

  • 1. SIMULATION OF THERMAL STRESSES IN A DISC BRAKE MADE BY AYUSH DEWANGAN B.VENKAT SWAROOP HARISH CHANDRA GUIDED BY MR.CHANDRA SHEKHAR SAHU ( Asst.Profesor ) MECHANICAL DEPT.
  • 2. The heat flux produced from the friction between a disc and pad system leads to a high temperature which causes thermal stresses in the disc and after a number of repeated braking cycles, cracks might be initiated. The finite element analysis (FEA) is performed to determine the temperatures profile in the disc and to analyze the stresses for the repeated braking, which could be used to calculate the fatigue life of a disc. THESIS WORK 2012 PRODUCT DEVELOPMENT AND MATERIALS ENGINEERING This thesis work has been carried out at the School of Engineering in Jönköping in the subject area Product Development and Materials Engineering. The work is a part of the master’s degree. The authors take full responsibility for the given opinions, conclusions and findings. MADE BY- ASNAF AZIZ AND JIYUE TAO
  • 3. During braking, the kinetic energy of the moving vehicle is converted into heat energy due to friction between disc and pad. As a result the temperature of the disc in contact with the pad is suddenly increased. Upon cooling the heat is dissipated by convection and radiation leaving some residual thermal stresses. Plastic deformation occurs due to large thermal expansion/contraction. After repeated number of braking cycles, cracks might be initiated on the disc surface which leads to failure. Theoretical background for plasticity, flow rules and hardening models is presented in very detail manner. The work on the heat analysis and thermo-mechanical contact problem is also studied.
  • 4. OBJECTIVE The thermo-mechanical contact problem is divided into two parts for analysis, heat problem and stress problem. The finite element method is used to obtain the temperature, thermal stresses and strains for the disc-pad system. To investigate the elastic-plastic thermal stress analysis for a brake disc under cyclic temperature gradients, the plasticity theory and flow rules are discussed. Proper consideration is also given to the material hardening models. In this thesis, the disc-pad system is studied only for few repeated braking cycles so that to establish the background for predicting the low cycle fatigue life (based on plastic strain amplitude) of the disc brake, which is the ultimate objective of this whole project.