The document discusses the optimization of the design of a brake drum for a two-wheeler through reverse engineering using ANSYS software. The authors create CAD models of an existing brake drum and analyze it using finite element analysis to determine stresses and temperature variations under different braking conditions and materials. Their results show that a CE alloy material produces less deformation and lower maximum temperatures than aluminum. They conclude that CE alloys can improve braking performance and are a better candidate material for brake drums compared to aluminum.
In the existing automobile market which is growing, the competition for better automobile in climbing up enormously. The racing fans involved will surely know the importance of a good brake system not only for safety but also for staying competitive in every race though Brake is the key factor for safety. Braking is a process which converts the kinetic energy of the automobile into mechanical energy for arresting the rotation of the road wheels which must be dissipated in the form of heat.
A balance bar (also called a bias bar) on dual master cylinder systems, divides the force from the brake pedal to the two master cylinders . It is called a “balance bar” because that is exactly what it does.
Analysis of Brake Biasing (Balance Bar) on BAJA (ATV) vehicleAditya Deshpande
In this report, I have done analysis of braking system for All Terrain Vehicle for BAJA competition. The report comprises thoroughly about brake biasing methods, and their uses. Here Balance bar method is discussed and analysed with mathematical formulas and subsequent conclusions are drawn.
The system was developed for VIT's Team Endurance Racing in year 2016 and successfully implemented.
I hope you find this report useful.
Do let me know your thoughts. Hit like and share this.
Aditya Deshpande
In the existing automobile market which is growing, the competition for better automobile in climbing up enormously. The racing fans involved will surely know the importance of a good brake system not only for safety but also for staying competitive in every race though Brake is the key factor for safety. Braking is a process which converts the kinetic energy of the automobile into mechanical energy for arresting the rotation of the road wheels which must be dissipated in the form of heat.
A balance bar (also called a bias bar) on dual master cylinder systems, divides the force from the brake pedal to the two master cylinders . It is called a “balance bar” because that is exactly what it does.
Analysis of Brake Biasing (Balance Bar) on BAJA (ATV) vehicleAditya Deshpande
In this report, I have done analysis of braking system for All Terrain Vehicle for BAJA competition. The report comprises thoroughly about brake biasing methods, and their uses. Here Balance bar method is discussed and analysed with mathematical formulas and subsequent conclusions are drawn.
The system was developed for VIT's Team Endurance Racing in year 2016 and successfully implemented.
I hope you find this report useful.
Do let me know your thoughts. Hit like and share this.
Aditya Deshpande
It is obvious that vehicle weight has a linear relationship
with the energy to be dissipated (stored) and the change
in velocity required has a exponential relationship.
• Deceleration times and stopping distances vary
somewhat for all vehicles on a given road surface.
• It should then be obvious that sizing the brake system
components has critical importance with respect to the
potential vehicle velocity and the mass of the vehicle.
• Note that heavy trucks generally have greater stopping
distances as compared to typical passenger cars.
Design of half shaft and wheel hub assembly for racing carRavi Shekhar
The Half - Shaft and Wheel Hub of Formula One racing car was designed taking into consideration one of the popular model of Redbull racing car. The various dimension of shaft and hub were altered to attain maximum factor of safety.
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.
Design analysis of the roll cage for all terrain vehicleeSAT Journals
Abstract We have tried to design an all terrain vehicle that meets international standards and is also cost effective at the same time. We have focused on every point of roll cage to improve the performance of vehicle without failure of roll cage. We began the task of designing by conducting extensive research of ATV roll cage through finite element analysis. A roll cage is a skeleton of an ATV. The roll cage not only forms the structural base but also a 3-D shell surrounding the occupant which protects the occupant in case of impact and roll over incidents. The roll cage also adds to the aesthetics of a vehicle. The design and development comprises of material selection, chassis and frame design, cross section determination, determining strength requirements of roll cage, stress analysis and simulations to test the ATV against failure. Keywords: Roll cage, material, finite element analysis, strength
For my Senior Design class, we designed and built a formula style car and competed with it against 40 other schools. This presentation was to explain to the faculty and other students what our design plans were for the vehicle and where our deisgn was at that point of the summer.
The Baja SAE Series is an annual competition organized by the Society of Automotive Engineers and has the objective to encourage undergraduate students to design, manufacture and test and All-Terrain vehicle prototype. There are almost 100 participants and it was a good opportunity to put in practice the knowledge acquired in class. In 2010 we achieved the 1st place in design, it has been the highest achievement in the whole team’s history, and it was of course a consequence of our hard work. As Powertrain head I led several tests in order to characterize the dynamical behavior of the vehicle, these developments settles a good base for future generations.
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.
A brief slideshow outlining the creative journey taken thus far in improving the ts_17 halfshafts and tripods in an attempt to achieve better race car performance.
It is obvious that vehicle weight has a linear relationship
with the energy to be dissipated (stored) and the change
in velocity required has a exponential relationship.
• Deceleration times and stopping distances vary
somewhat for all vehicles on a given road surface.
• It should then be obvious that sizing the brake system
components has critical importance with respect to the
potential vehicle velocity and the mass of the vehicle.
• Note that heavy trucks generally have greater stopping
distances as compared to typical passenger cars.
Design of half shaft and wheel hub assembly for racing carRavi Shekhar
The Half - Shaft and Wheel Hub of Formula One racing car was designed taking into consideration one of the popular model of Redbull racing car. The various dimension of shaft and hub were altered to attain maximum factor of safety.
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.
Design analysis of the roll cage for all terrain vehicleeSAT Journals
Abstract We have tried to design an all terrain vehicle that meets international standards and is also cost effective at the same time. We have focused on every point of roll cage to improve the performance of vehicle without failure of roll cage. We began the task of designing by conducting extensive research of ATV roll cage through finite element analysis. A roll cage is a skeleton of an ATV. The roll cage not only forms the structural base but also a 3-D shell surrounding the occupant which protects the occupant in case of impact and roll over incidents. The roll cage also adds to the aesthetics of a vehicle. The design and development comprises of material selection, chassis and frame design, cross section determination, determining strength requirements of roll cage, stress analysis and simulations to test the ATV against failure. Keywords: Roll cage, material, finite element analysis, strength
For my Senior Design class, we designed and built a formula style car and competed with it against 40 other schools. This presentation was to explain to the faculty and other students what our design plans were for the vehicle and where our deisgn was at that point of the summer.
The Baja SAE Series is an annual competition organized by the Society of Automotive Engineers and has the objective to encourage undergraduate students to design, manufacture and test and All-Terrain vehicle prototype. There are almost 100 participants and it was a good opportunity to put in practice the knowledge acquired in class. In 2010 we achieved the 1st place in design, it has been the highest achievement in the whole team’s history, and it was of course a consequence of our hard work. As Powertrain head I led several tests in order to characterize the dynamical behavior of the vehicle, these developments settles a good base for future generations.
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.
A brief slideshow outlining the creative journey taken thus far in improving the ts_17 halfshafts and tripods in an attempt to achieve better race car performance.
Development of Software Using Matlab for Design Optimization of Brake for Min...iosrjce
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.
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.
In the modern day and age where automobiles are an essential part of our day to day life, the requirements of each are different. Some demand for a high-performance machine whereas others require a comfortable ride. The modern engineering helps in achieving all the aspects of a safe, reliable and fast vehicle. With the change in time, the need for an all-terrain vehicle has gradually increased. The research paper includes the optimisation of braking system for minimum stopping distance and locking all four tyres simultaneously. The SolidWorks struct-static analysis and simulation are done to obtain a better braking system which can provide the best in class arrangements for the customer. The research focused on disc, master cylinder position. The designs provide the sturdiness and durability which is the primary requirement for an all-terrain vehicle. The study comprises of braking for BAJA-ATV. The all-terrain conditions require active braking and all wheels locking at the instant time. The research paper includes the parameters for the efficient disc, callipers, master cylinder position for effective braking.
“EFFICYCLE” derived from Efficient-Cycle promote the objective of providing opportunity to the students to conceive, design and fabricate a three wheel configuration vehicle powered by human-electric hybrid power and capable of seating two passengers catering to the day to day mobility needs. The vehicle must be aerodynamic, engineered for performance & safety and ergonomically designed. The objective is to promote innovation and generate consciousness among st the young engineers towards environment friendly mobility solution.
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
The standard disc brake of a 4-wheeler model was done using Autodesk Mechanical Simulation through which the properties like deflection, heat flux and temperature of disc brake model were calculated. It is important to understand action force and friction force on the disc brake new material, how disc brake works more efficiently, which can help to reduce the accident that may happen at anytime.
Design and Analysis of Disc Brake for Low Brake SquealIJLT EMAS
Vibration induced due to friction in disc brake is a
theme of major interest and related to the automotive industry.
Squeal noise generated during braking action is an indication of
a complicated dynamic problem which automobile industries
have faced for decades. For the current study, disc brake of 150
cc is considered. Vibration and sound level for different speed
are measured. Finite element and experimentation for modal
analysis of different element of disc brake and assembly are
carried out. In order to check that precision of the finite element
with those of experimentation, two stages are used both
component level and assembly level. Mesh sensitivity of the disc
brake component is considered. FE updating is utilized to reduce
the relative errors between the two measurements by tuning the
material. Different viscoelastic materials are selected and
constrained layer damping is designed. Constrained layer
damping applied on the back side of friction pads and compared
vibration and sound level of disc brake assembly without
constrained layer damping with disc brake assembly having
constrained layer. It was observed that there were reduction in
vibration and sound level. Nitrile rubber is most effective
material for constrained layer damping.
UiPath Test Automation using UiPath Test Suite series, part 3DianaGray10
Welcome to UiPath Test Automation using UiPath Test Suite series part 3. In this session, we will cover desktop automation along with UI automation.
Topics covered:
UI automation Introduction,
UI automation Sample
Desktop automation flow
Pradeep Chinnala, Senior Consultant Automation Developer @WonderBotz and UiPath MVP
Deepak Rai, Automation Practice Lead, Boundaryless Group and UiPath MVP
Accelerate your Kubernetes clusters with Varnish CachingThijs Feryn
A presentation about the usage and availability of Varnish on Kubernetes. This talk explores the capabilities of Varnish caching and shows how to use the Varnish Helm chart to deploy it to Kubernetes.
This presentation was delivered at K8SUG Singapore. See https://feryn.eu/presentations/accelerate-your-kubernetes-clusters-with-varnish-caching-k8sug-singapore-28-2024 for more details.
GraphRAG is All You need? LLM & Knowledge GraphGuy Korland
Guy Korland, CEO and Co-founder of FalkorDB, will review two articles on the integration of language models with knowledge graphs.
1. Unifying Large Language Models and Knowledge Graphs: A Roadmap.
https://arxiv.org/abs/2306.08302
2. Microsoft Research's GraphRAG paper and a review paper on various uses of knowledge graphs:
https://www.microsoft.com/en-us/research/blog/graphrag-unlocking-llm-discovery-on-narrative-private-data/
Essentials of Automations: Optimizing FME Workflows with ParametersSafe Software
Are you looking to streamline your workflows and boost your projects’ efficiency? Do you find yourself searching for ways to add flexibility and control over your FME workflows? If so, you’re in the right place.
Join us for an insightful dive into the world of FME parameters, a critical element in optimizing workflow efficiency. This webinar marks the beginning of our three-part “Essentials of Automation” series. This first webinar is designed to equip you with the knowledge and skills to utilize parameters effectively: enhancing the flexibility, maintainability, and user control of your FME projects.
Here’s what you’ll gain:
- Essentials of FME Parameters: Understand the pivotal role of parameters, including Reader/Writer, Transformer, User, and FME Flow categories. Discover how they are the key to unlocking automation and optimization within your workflows.
- Practical Applications in FME Form: Delve into key user parameter types including choice, connections, and file URLs. Allow users to control how a workflow runs, making your workflows more reusable. Learn to import values and deliver the best user experience for your workflows while enhancing accuracy.
- Optimization Strategies in FME Flow: Explore the creation and strategic deployment of parameters in FME Flow, including the use of deployment and geometry parameters, to maximize workflow efficiency.
- Pro Tips for Success: Gain insights on parameterizing connections and leveraging new features like Conditional Visibility for clarity and simplicity.
We’ll wrap up with a glimpse into future webinars, followed by a Q&A session to address your specific questions surrounding this topic.
Don’t miss this opportunity to elevate your FME expertise and drive your projects to new heights of efficiency.
LF Energy Webinar: Electrical Grid Modelling and Simulation Through PowSyBl -...DanBrown980551
Do you want to learn how to model and simulate an electrical network from scratch in under an hour?
Then welcome to this PowSyBl workshop, hosted by Rte, the French Transmission System Operator (TSO)!
During the webinar, you will discover the PowSyBl ecosystem as well as handle and study an electrical network through an interactive Python notebook.
PowSyBl is an open source project hosted by LF Energy, which offers a comprehensive set of features for electrical grid modelling and simulation. Among other advanced features, PowSyBl provides:
- A fully editable and extendable library for grid component modelling;
- Visualization tools to display your network;
- Grid simulation tools, such as power flows, security analyses (with or without remedial actions) and sensitivity analyses;
The framework is mostly written in Java, with a Python binding so that Python developers can access PowSyBl functionalities as well.
What you will learn during the webinar:
- For beginners: discover PowSyBl's functionalities through a quick general presentation and the notebook, without needing any expert coding skills;
- For advanced developers: master the skills to efficiently apply PowSyBl functionalities to your real-world scenarios.
Kubernetes & AI - Beauty and the Beast !?! @KCD Istanbul 2024Tobias Schneck
As AI technology is pushing into IT I was wondering myself, as an “infrastructure container kubernetes guy”, how get this fancy AI technology get managed from an infrastructure operational view? Is it possible to apply our lovely cloud native principals as well? What benefit’s both technologies could bring to each other?
Let me take this questions and provide you a short journey through existing deployment models and use cases for AI software. On practical examples, we discuss what cloud/on-premise strategy we may need for applying it to our own infrastructure to get it to work from an enterprise perspective. I want to give an overview about infrastructure requirements and technologies, what could be beneficial or limiting your AI use cases in an enterprise environment. An interactive Demo will give you some insides, what approaches I got already working for real.
Connector Corner: Automate dynamic content and events by pushing a buttonDianaGray10
Here is something new! In our next Connector Corner webinar, we will demonstrate how you can use a single workflow to:
Create a campaign using Mailchimp with merge tags/fields
Send an interactive Slack channel message (using buttons)
Have the message received by managers and peers along with a test email for review
But there’s more:
In a second workflow supporting the same use case, you’ll see:
Your campaign sent to target colleagues for approval
If the “Approve” button is clicked, a Jira/Zendesk ticket is created for the marketing design team
But—if the “Reject” button is pushed, colleagues will be alerted via Slack message
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And...
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Charlie Greenberg, Host
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Sr Director, Infrastructure Ecosystem, Arm.
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All of this illustrated with link prediction over knowledge graphs, but the argument is general.
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"Impact of front-end architecture on development cost", Viktor TurskyiFwdays
I have heard many times that architecture is not important for the front-end. Also, many times I have seen how developers implement features on the front-end just following the standard rules for a framework and think that this is enough to successfully launch the project, and then the project fails. How to prevent this and what approach to choose? I have launched dozens of complex projects and during the talk we will analyze which approaches have worked for me and which have not.
Leading Change strategies and insights for effective change management pdf 1.pdf
K012447075
1. IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE)
e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 12, Issue 4 Ver. IV (Jul. - Aug. 2015), PP 70-75
www.iosrjournals.org
DOI: 10.9790/1684-12447075 www.iosrjournals.org 70 | Page
Optimization of Design of Brake Drum of Two Wheeler through
Approach of Reverse Engineering by Using Ansys Software
Meenakshi Kushal1
Suman Sharma2
1
ME Persuing, Department of Mechanical Engineering
TRUBA College of Engineering & Technology, Indore, India.
2
Professor, Department of Mechanical Engineering
TRUBA College of Engineering & Technology, Indore, India.
Abstract: The aim of this article is to optimize the design of Hero Honda Passion brake drum (i.e. through
reverse engineering approach). Optimization is done by changing the material of the brake drum, under
different braking time and operational conditions. Brake drum is optimized to obtained different stresses,
deformation values, rise in temperature on different braking time and heat transfer rate. Optimized results
obtained are compared for Aluminium and CE (Controlled Expansion) material alloys. It concludes that the CE
(Controlled Expansion) alloys can be a better candidate material for the brake drum applications of light
commercial vehicles and it also increases the braking performance.
Keywords: Brake drum, Al alloy brake drum, CE alloy brake drum, Computer Aided Modeling, Finite Element
Analysis, Inventor professional, Ansys workbench.
I. Introduction
Drum brakes were the first types of brakes used on motor vehicles. Nowadays, over 100 years after the
first usage, drum brakes are still used on the rear wheels of most vehicles. The drum brake is used widely as the
rear brake particularly for small car and motorcycle. The leading-trailing shoe design is used extensively as rear
brake on passenger cars and light weight pickup trucks. Most of the front-wheel-drive vehicles use rear leading-
trailing shoe brakes. Such design provided low sensitivity to lining friction changes and has stable torque
production (Limpert, 1999).[1] A brake is a mechanical device which is used to absorb the energy possessed by
a moving system or mechanism by means of friction. The primary purpose of the brake is to slow down or
completely stop the motion of a moving system, such as a rotating disc/drum, machine or vehicle. Many aspects
of slowing and stopping a vehicle are controlled by simple physics dealing with the deceleration of a body in
motion. The simplest way to stop a vehicle is to convert the kinetic energy into heat energy. The energy
absorbed by brakes is dissipated in the form of heat. The heat is dissipated in surrounding, air, water etc. [2]
The braking equipment of a vehicle includes all of its brake system that is all of reducing velocity of a
moving vehicle, reducing its rate of acceleration, increasing its rate of deceleration, halting the acceleration,
increasing its rate of deceleration, halting the vehicle and preventing the vehicle from returning movement once
it is stationary. [3]
A drum brake is a brake that uses friction caused by a set of shoes or pads that press against a rotating
drum shaped part called a brake drum. The brake drum is generally made of cast iron that rotates with the wheel.
When a driver applies the brakes, the lining pushes radially against the inner surface of the drum, and the
ensuing friction slows or stops rotation of the wheel and axle, and thus the vehicle.
Internal expanding shoe brakes are most commonly used in automobiles. In an automobile, the wheel is
fitted on a wheel drum. The brake shoes come in contact with inner surface of this drum to apply brakes. The
whole assembly consists of a pair of brake shoes along with brake linings, a retractor spring two anchor pins a
cam and a brake drum. Brake linings are fitted on outer surface of each brake shoe. The brake shoes are hinged
at one end by anchor pins. Other end of brake shoe is operated by a cam to expand it out against brake drum. A
retracting spring brings back shoes in their original position when brakes are not applied. The brake drum
Braking System closes inside it the whole mechanism to protect it from dust and first. A plate holds whole
assembly and fits to car axle. It acts as a base to fasten the brake shoes and other operating mechanism
Braking power is obtained when the brake shoes are pushed against the inner surface of the drum
which rotates together with the axle. Drum brakes are mainly used for the rear wheels of passenger cars and
trucks while disc brakes are used exclusively for front brakes because of their greater direction stability. The
backing plate is a pressed steel plate, bolted to the rear axle housing. Since the brake shoes are fitted to the
backing plate, all of the braking force acts on the backing plate.
A drum brake has a hollow drum that turns with the wheel. Its open back is covered by a stationary
back plate on which there are two curved shoes carrying friction linings. The shoes are forced outwards by
2. Optimization of Design of Brake Drum of Two Wheeler through Approach of Reverse Engineering ….
DOI: 10.9790/1684-12447075 www.iosrjournals.org 71 | Page
hydraulic pressure moving pistons in the brake’s wheel cylinders, so pressing the linings against the inside of
the drum to slow or stop it.[4]
Optimal design of today's brake systems is found using additional calculations based on Finite element
methods. For both types of brake systems, drum brakes and disk brakes. Results include deformation, stress
distribution, contact pressure and showing which regions of the contact area are in sticking or sliding condition.
[5] A parametric modeling of a drum brake based on 3-D Finite Element Methods for non-contact analysis is
presented. Many parameters are examined during this study such as the effect of drum-lining interface stiffness,
coefficient of friction, and line pressure on the interface contact. It is shown that the Unsymmetrical modal
analysis is efficient enough to solve this linear problem after transforming the non-linear behavior of the contact
between the drum and the lining to a linear behavior. [6] A multi objective optimization design model of drum
brake with the goals of maximizing the efficiency factor of braking, minimizing the volume of drum brake, and
minimizing the temperature rise of brake, in order to better meet the requirements of engineering practice. And
the results of optimizing the new brake model indicate that DECell obviously outperforms the compared popular
algorithm NSGA-II concerning the number of obtained brake design parameter sets, the speed, and stability for
finding them. It is an effective algorithm that can be applied to solve the drum brake parameters optimization
and other complicated engineering problems. [7] To establish a brake test rig capable of measuring the
performance of a drum brake at different operational and environmental conditions, the effects of dry and humid
environment are considered under different applied forces and vehicle sliding speed. The experimental results
showed a slight increase in the friction coefficients between drum and brake lining with increasing pressure or
speed at dry and wet conditions. [8] Brake torque is reduced in the absence of cooling so the result shows to
eliminate brake fade if the cooling is very effective. Brake fading is due to temperature rise of brake shoe and
brake drum. The heat generated due to braking rises the temperature reducing the coefficient of friction at the
interface of brake shoe and brake drum. The reduced coefficient of friction reduces the brake torque, thus
reduces the brake effectiveness. It was observed that brake torque was reduced by 25% in the absence of cooling
as the brake cooling improved the brake fade reduced(Brake torque improved).[9]
II. Methods And Material
To create the cad model of the brake drum we find the existing brake drum of Hero Honda Passion
from market for reverse engineering. We can measure all the visible dimensions manually with specified
measuring instruments to create accurate and scaled model. To find out accurate feature location like holes plane
angles etc.CMM is done. Using CAD software we can create CAD model of brake drum as per measurement
data we Import the CAD Model (IGES) in the Ansys Workbench 14.5 for pre-processing and then the stress and
thermal analysis is done on the brake drum. The Analysis involves the discritization called meshing, boundary
conditions and loading. For analysis we take Aluminium with aluminium alloys and controlled expansion alloys
as the material .The Aluminium has been selected based on the properties required for the existing brake drum.
The aluminium alloys has been selected as matrix for manufacturing the MMC based on the ease of
manufacturing.
Specifications of brake drum
Inner diameter (mm) = 110.
Outer diameter (mm) = 164
Outer Width (mm) = 10
Inner Width (mm) = 38
Contact an angle per shoe = 120
Width of Shoe (mm) = 25
No. of shoes = 2
Material properties of brake drum
3. Optimization of Design of Brake Drum of Two Wheeler through Approach of Reverse Engineering ….
DOI: 10.9790/1684-12447075 www.iosrjournals.org 72 | Page
Solid Modeling: The first step was to prepare a solid model of the brake drum. This was carried out by using
Inventor professional 2012 Software.
Analysis: Brake drum finite element analysis is done through Ansys workbench 14.0 software. Both stress
analysis and thermal analysis is done under different braking time and operational conditions.
Boundary Conditions: For Stress analysis, pressure is applied on the internal surface of the cylindrical face of
the brake drum, and the hub of the brake drum where the wheel of the vehicle rests is supported with the fixed
support.
Deformation for Aluminium Deformation for CE17
Stresses for Aluminum Stresses for C17
Thermal Analysis: For thermal analysis we assign the calculated heat flux on the inner face of brake drum. We
calculate the heat flux on two conditions:
1. Gradual braking (time=15sec) at 80kmph
2. Sudden braking (time=5 sec)at 80kmph
Boundary Conditions: For heat transfer analysis heat flux is applied on the internal surface of the cylindrical
face of the brake drum, and the hub of the brake drum where the wheel of the vehicle rests is supported with the
fixed support.
4. Optimization of Design of Brake Drum of Two Wheeler through Approach of Reverse Engineering ….
DOI: 10.9790/1684-12447075 www.iosrjournals.org 73 | Page
Gradual braking for Aluminium Gradual braking for CE17
Sudden braking for aluminium Sudden braking for CE17
III. Results
Table 1 for deformation of materials
S.no. Material Deformation(mm)
Max Min.
1 Aluminium 0.007794 0.0021819
2 LM28 0.005308 0.0010044
3 LM29 0.000615 0.000011714
4 A356 0.000486 1.6286E-07
5 CE13 0.000505 9.738E-08
6 CE17 0.000588 1.1021E-07
Table 2 for gradual braking temp.variation
S.no. Material Max.temp Outer
face
temp.
Heat
transferred
at outer
surface
1 Aluminium 610 414 196
2 LM28 700.42 474.28 226.14
3 LM29 714.52 483.68 230.84
4 A356 650.01 488 162.01
5 CE13 617.62 419 198.62
6 CE17 600.23 400 200.23
5. Optimization of Design of Brake Drum of Two Wheeler through Approach of Reverse Engineering ….
DOI: 10.9790/1684-12447075 www.iosrjournals.org 74 | Page
Table 3 for sudden braking temp.variation
S.no Material Max
temp
Outer face
temp.
Heat transferred
at outer surface
1. Aluminium 1789.7 1200 589.7
2. LM28 2057.6 1379.1 678.5
3. LM29 2099.8 1407.2 692.6
4. A356 1880.2 1500 380.2
5. CE13 1808.9 1213.2 595.7
6. CE17 1756.7 1165.5 591.2
Variation in deformation
Variation in Heat transfer for gradual braking at 80Kmph
Variation in Heat transfer for sudden braking at 80Kmph
6. Optimization of Design of Brake Drum of Two Wheeler through Approach of Reverse Engineering ….
DOI: 10.9790/1684-12447075 www.iosrjournals.org 75 | Page
IV. Conclusion
The deformation and the stress induced in the aluminium alloy and CE (Controlled Expansion) alloy
brake drums during the application of brake force have been determined using finite element analysis. It is
observed from the analysis that the deformation in CE (Controlled Expansion) alloy brake drum is considerably
less than the Aluminium alloy brake drum.
The stresses in the CE (Controlled Expansion) alloy and Al alloy brake drums are found to be almost
same. There is negligible variation in them. Hence, the required factor of safety is maintained in both the CE
(Controlled Expansion) alloy and Al alloy brake drums. While braking from a speed of 80km/h at a constant
deceleration of4.44 m/sec2 at sudden braking and 1.481m/sec2 at gradual braking, it is observed that the
temperature rise in CE (Controlled Expansion) alloy brake drums surface is less than the Al alloy brake drums
and the heat transferred at the outer surface of the brake drum increases. It increases the life of lining material
and the temperature rise in brake components is reduced which will increase the braking performance. During
sudden braking, the temperature rise in brake drum is found to be 65 to 66 % more than the gradual braking. It
concludes that temperature rise in the surface of brake drum also depends upon the time of braking. A
comparative study has been conducted between CE (Controlled Expansion) alloy and Al alloy brake drums
based on weight, temperature rise and deformation. The CE (Controlled Expansion) alloys brake drum has
comparatively less weight than Pure Aluminium and Aluminium alloys brake drum. CE (Controlled Expansion)
alloys have low expansion, stiffer, excellent machinibility as compared to Pure Aluminium and Aluminium
alloys.
From the above observations, it is concluded that the CE (Controlled Expansion) alloy brake drum has
less weight, less deformation, minimum temperature at the surface. Hence, the CE (Controlled Expansion)
alloys can be a better candidate material for the brake drum applications of light commercial vehicles.
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