29-09-2016, 10:28 AM
1456729193-FINALPAPERIEEE.doc (Size: 1.1 MB / Downloads: 5)
Abstract—Braking system is one of the most essential functions of an automobile. Therefore, it is a must for all vehicles to have proper brake system. Due to critical system in the vehicle, many of researchers have conducted a study on brake system and its entire component. In this project, we has conducted a study on normal & drilled disc brake rotor of normal passenger vehicle with full load of capacity. The study is more likely concern of heat and temperature distribution on disc brake rotor .The motive of undertaking this project of “Thermal Analysis of Disc Brake” is to study and evaluate the performance under severe braking conditions and there by assist proper design of disc rotor out of thermal analysis. Transient state response has been conducted through the heat transfer analysis where to predict the worse case scenario and temperature behaviors of disc brake rotor. In this study, finite element analysis approached has been conducted in order to identify the temperature distributions and behaviors of disc brake rotor in transient responses. Ansys has been used as finite elements software to perform the thermal analysis on responses. Thus, results provide better understanding on the thermal characteristic of disc brake rotor and assist the automotive industry in developing optimum and effective disc brake rotor.
.INTRODUCTION
Brakes are most important safety parts in the vehicles. Generally all of the vehicles have their own safety devices. Brakes function to slow and stop the rotation of the wheel. To stop the wheel, braking pads are forced mechanically against the rotor on both surfaces. They are compulsory for all of the modern vehicles and the safe operation of vehicles. In short, brakes transform the kinetic energy of the vehicle into heat energy, thus slowing its speed.
The braking system must be decelerate a vehicle in a controlled and repeatable fashion and when appropriate cause the vehicle to stop. The braking should permit the vehicle to maintain a constant speed when traveling downhill. The braking system must hold the vehicle stationary when on the flat or on a gradient.
Nowadays, there are lot of software has been developed in order to cater the modeling and the finite element analysis on the vehicle component such as (Automatic Dynamic of Mechanical Systems), SOLIDWORKS, ANSYS. There is an advantage of using that powerful computational analysis software where by using those would make it easier, less cost better accuracy and less computing time. Most of the software is used in the wide range of industries such as automotive, oil and gas, aerospace, marine, heavy duty engineering, construction, electro-mechanical and general mechanical industries. In this project, design package SOLIDWORKS and finite element package will be used to generate model and run analysis on the chosen component.
II.STATEMENT OF PROBLEM
Beside overall automotive parts, like engines, there are more crucial parts that engineers need to look into consideration. Suspension, brake, electrical, hydraulic and gear are all the crucial systems in the automotive areas. Each of the parts has their own functionality which brings life to the automation industries. Brakes are the crucial system in stopping the vehicle on all moving stages including braking during high speed, sharp cornering, traffic jam and downhill. All of those braking moments give a different value of temperature distribution and thermal stress. Good performance of disc brake rotor comes from good material with better mechanical and thermal properties. Good designs of disc brake rotor are varying across the range of the vehicles. There are different design and performance of disc brake rotor if compared between passenger, commercial and heavy duty vehicle. There are also other constraints such as cost, weight, manufacturing capability, robustness and reliability, packaging, maintenance and servicing.
This paper concerns of the temperature distribution and constraint of the disc brake rotor. Most of the vehicles today have disc brake rotors that are made of grey cast iron Grey cast iron is chosen for its relatively high thermal conductivity, high thermal diffusivity and low cost . In this paper, we will investigate on the thermal issues of normal two wheeler motor vehicle disc brake rotor, where the investigation is to determine the temperature behavior of the disc brake rotor due to severe braking of the disc brake rotor by using Finite Element Analysis (FEA).
Braking performance of a vehicle can be significantly affected by the temperature rise in the brake components. High temperature during braking will caused to Brake fade, premature wear, Brake fluid vaporization, Bearing failure, Thermal cracks, Thermally-excited vibration. Therefore, it is important to study and predict the temperature rise of a given brake component and assess its thermal performance in the early design stage. Finite element analysis (FEA) has been preferred and chosen method to investigate some of the above concerns such as disc brake rotor temperature rise and thermal cracks.
III.RESEARCH METHODOLOGY
Begin with a literature review, a lot of paper and journal has been read up and a part of it has been considered in this paper. Meanwhile, vernier calipers and steel rule used to measure the major coordinate of real disc brake rotor. Later, the precise dimensions have been used to translate in 2D and 3D drawing by using SOLIDWORKS.
In the second stage, load analysis has been done where the heat flux and convectional heat transfer coefficients has been calculated. Load analysis calculated based on full load of passenger in the two wheeler vehicle. Later, value of load analysis has been applied on finite element analysis. Next fractional 3D model of disc brake rotor has been transfer to hyper mesh where the inputs are given. Assigning material properties, load and meshing of the model has been done in this stages. Then, completed meshing model has been submitted for analysis. Now the 3D model of disc brake rotor has been transfer to finite element software which is ANSYS. Thermal analysis has been done on transient responses. Finally an expected result from the transient responses of thermal analysis has been obtained.