03-07-2014, 04:11 PM
DESIGN, STRUCTURAL “AND” THERMAL ANALYSIS OF DISC BRAKE
[attachment=65603]
Abstract
The disc brake is a device for slowing or stopping the rotation of a wheel. A brake disc (or rotor), usually made of
cast iron or ceramic composites (including carbon, Kevlar and silica), is connected to the wheel and/or the axle.
To stop the wheel, friction material in the form of brake pads (mounted on a device called a brake caliper) is
forced mechanically, hydraulically, pneumatically or electromagnetically against both sides of the disc. Friction
causes the disc and attached wheel to slow or stop. Brakes convert friction to heat, but if the brakes get too hot,
they will cease to work because 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.The aim of the project is to design, model a disc brake. Modeling is done using Pro/Engineer.
Structural and Thermal analysis is to be done on the disc brakes using two materials Stainless Steel and Carbon
Steel.Structural analysis is done on the disc brake to validate the strength of the disc brake and thermal analysis is
done to analyze the thermal properties. Comparison can be done for displacement, stresses, thermal gradient etc.
for the two materials to check which material is best.We are also providing manufacturing process for making disc
brake and also preparing prototype. Manufacturing process is done using Pro/Engineer.Pro/Engineer is a 3d
modeling software widely used in the design process. ANSYS is general-purpose finite element analysis (FEA)
software package. Finite Element Analysis is a numerical method of deconstructing a complex system into very
small pieces (of user-designated size) called elements.
INTRODUCTION
Computer-aided design (CAD), also known as
computer-aided design and drafting (CADD).CAD
describes the process of drafting with a computer , and
the output of CAD must convey information, such as
materials, processes, dimensions, and tolerances,
according to application-specific conventions.CADD
describes the purpose of streamlining design processes,
drafting, documentation, and manufacturing
processes.CAD is mainly used for detailed engineering
of 3D models and/or 2D drawings of physical
components, but it is also used throughout the
engineering process from conceptual design and layout
of products, through strength and dynamic analysis of
assemblies to definition of manufacturing methods of
components. It can also be used to design objects.CAD
has become an especially important technology within
the scope of computer-aided technologies, with benefits
such as lower product development costs and a greatly
shortened design cycle. CAD enables designers to lay
out and develop work on screen, print it out and save it
for future editing, saving time on their drawings.
Pro/ENGINEER Wildfire is the standard in 3D product
design, featuring industry-leading productivity tools
that promote best practices in design while ensuring
compliance with your industry and company standards.
INTRODUCTION TO FEA
FEA consists of a computer model of a material or
design that is stressed and analyzed for specific results.
It is used in new product design, and existing product
refinement. A company is able to verify a proposed
design will be able to perform to the client's
specifications prior to manufacturing or construction.
Modifying an existing product or structure is utilized to
qualify the product or structure for a new service
condition. In case of structural failure, FEA may be
used to help determine the design modifications to meet
the new condition. FEA uses a complex system of
points called nodes which make a grid called a mesh.
This mesh is programmed to contain the material and
structural properties which define how the structure will
react to certain loading conditions. Nodes are assigned
at a certain density throughout the material depending
on the anticipated stress levels of a particular area.In
practice, a finite element a
INTRODUCTION TO ANSYS
ANSYS is general-purpose finite element analysis
(FEA) software package. Finite Element Analysis is a
numerical method of deconstructing a complex system
into very small pieces (of user-designated size) called
elements. The software implements equations that
govern the behaviour of these elements and solves them
all; creating a comprehensive explanation of how the
system acts as a whole. These results then can be
presented in tabulated, or graphical forms. This type of
analysis is typically used for the design and
optimization of a system far too complex to analyze by
hand. Systems that may fit into this category are too
complex due
Definitions of Results obtained
Displacement - A vector quantity which refers to the
distance which an object has moved in a given
direction. It is measured as the length of a straight line
between the initial and final positions of a body.
Von Mises Stress - The Von Mises criteria is a formula
for combining these 3 stresses into an equivalent stress,
which is then compared to the tensile stress of the
material.
Nodal Temperature - A temperature can be applied to
nodes, surfaces, or parts in a model. A surface
temperature applies nodal temperatures to each node on
the surface, and a part temperature applies nodal
temperatures to each node in the part.
Thermal Gradient - A temperature gradient is a physical
quantity that describes in which direction and at what
rate the temperature changes the most rapidly around a
particular location.
As per the analysis images
Thermal flux - Heat flux or thermal flux is the rate of
heat energy transfer through a given surface.
The yield stress for Stainless Steel is 793Mpa.
The yield stress for Carbon Steel is 165Mpa
CONCLUSION
1. The disc brake is a device for slowing or stopping
the rotation of a wheel. In our project, we have designed
and modeled a disc brake.
2. Modeling is done using Pro/Engineer. We have
performed Structural and Thermal analysis using
Stainless steel and Carbon Steel on the disc brake.
3. From the structural analysis, by observing stress
values for both the materials, both the values are less
than their respective yield stresses. So we can decide
that our design is safe.
4. From thermal analysis, by observing the thermal
gradient for both the materials, the value is more for
Carbon Steel.
5. Thermal gradient is the rate of temperature change on
a surface. The rate of temperature change for brake
surface using carbon steel is more than that of using
stainless steel.
6. So we conclude that for our designed disc brake, the
better material is carbon steel.
7. To manufacture disc brake the following operations
are done:Turning, Cylindrical Grinding, Jig Boring,
Lapping
[attachment=65603]
Abstract
The disc brake is a device for slowing or stopping the rotation of a wheel. A brake disc (or rotor), usually made of
cast iron or ceramic composites (including carbon, Kevlar and silica), is connected to the wheel and/or the axle.
To stop the wheel, friction material in the form of brake pads (mounted on a device called a brake caliper) is
forced mechanically, hydraulically, pneumatically or electromagnetically against both sides of the disc. Friction
causes the disc and attached wheel to slow or stop. Brakes convert friction to heat, but if the brakes get too hot,
they will cease to work because 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.The aim of the project is to design, model a disc brake. Modeling is done using Pro/Engineer.
Structural and Thermal analysis is to be done on the disc brakes using two materials Stainless Steel and Carbon
Steel.Structural analysis is done on the disc brake to validate the strength of the disc brake and thermal analysis is
done to analyze the thermal properties. Comparison can be done for displacement, stresses, thermal gradient etc.
for the two materials to check which material is best.We are also providing manufacturing process for making disc
brake and also preparing prototype. Manufacturing process is done using Pro/Engineer.Pro/Engineer is a 3d
modeling software widely used in the design process. ANSYS is general-purpose finite element analysis (FEA)
software package. Finite Element Analysis is a numerical method of deconstructing a complex system into very
small pieces (of user-designated size) called elements.
INTRODUCTION
Computer-aided design (CAD), also known as
computer-aided design and drafting (CADD).CAD
describes the process of drafting with a computer , and
the output of CAD must convey information, such as
materials, processes, dimensions, and tolerances,
according to application-specific conventions.CADD
describes the purpose of streamlining design processes,
drafting, documentation, and manufacturing
processes.CAD is mainly used for detailed engineering
of 3D models and/or 2D drawings of physical
components, but it is also used throughout the
engineering process from conceptual design and layout
of products, through strength and dynamic analysis of
assemblies to definition of manufacturing methods of
components. It can also be used to design objects.CAD
has become an especially important technology within
the scope of computer-aided technologies, with benefits
such as lower product development costs and a greatly
shortened design cycle. CAD enables designers to lay
out and develop work on screen, print it out and save it
for future editing, saving time on their drawings.
Pro/ENGINEER Wildfire is the standard in 3D product
design, featuring industry-leading productivity tools
that promote best practices in design while ensuring
compliance with your industry and company standards.
INTRODUCTION TO FEA
FEA consists of a computer model of a material or
design that is stressed and analyzed for specific results.
It is used in new product design, and existing product
refinement. A company is able to verify a proposed
design will be able to perform to the client's
specifications prior to manufacturing or construction.
Modifying an existing product or structure is utilized to
qualify the product or structure for a new service
condition. In case of structural failure, FEA may be
used to help determine the design modifications to meet
the new condition. FEA uses a complex system of
points called nodes which make a grid called a mesh.
This mesh is programmed to contain the material and
structural properties which define how the structure will
react to certain loading conditions. Nodes are assigned
at a certain density throughout the material depending
on the anticipated stress levels of a particular area.In
practice, a finite element a
INTRODUCTION TO ANSYS
ANSYS is general-purpose finite element analysis
(FEA) software package. Finite Element Analysis is a
numerical method of deconstructing a complex system
into very small pieces (of user-designated size) called
elements. The software implements equations that
govern the behaviour of these elements and solves them
all; creating a comprehensive explanation of how the
system acts as a whole. These results then can be
presented in tabulated, or graphical forms. This type of
analysis is typically used for the design and
optimization of a system far too complex to analyze by
hand. Systems that may fit into this category are too
complex due
Definitions of Results obtained
Displacement - A vector quantity which refers to the
distance which an object has moved in a given
direction. It is measured as the length of a straight line
between the initial and final positions of a body.
Von Mises Stress - The Von Mises criteria is a formula
for combining these 3 stresses into an equivalent stress,
which is then compared to the tensile stress of the
material.
Nodal Temperature - A temperature can be applied to
nodes, surfaces, or parts in a model. A surface
temperature applies nodal temperatures to each node on
the surface, and a part temperature applies nodal
temperatures to each node in the part.
Thermal Gradient - A temperature gradient is a physical
quantity that describes in which direction and at what
rate the temperature changes the most rapidly around a
particular location.
As per the analysis images
Thermal flux - Heat flux or thermal flux is the rate of
heat energy transfer through a given surface.
The yield stress for Stainless Steel is 793Mpa.
The yield stress for Carbon Steel is 165Mpa
CONCLUSION
1. The disc brake is a device for slowing or stopping
the rotation of a wheel. In our project, we have designed
and modeled a disc brake.
2. Modeling is done using Pro/Engineer. We have
performed Structural and Thermal analysis using
Stainless steel and Carbon Steel on the disc brake.
3. From the structural analysis, by observing stress
values for both the materials, both the values are less
than their respective yield stresses. So we can decide
that our design is safe.
4. From thermal analysis, by observing the thermal
gradient for both the materials, the value is more for
Carbon Steel.
5. Thermal gradient is the rate of temperature change on
a surface. The rate of temperature change for brake
surface using carbon steel is more than that of using
stainless steel.
6. So we conclude that for our designed disc brake, the
better material is carbon steel.
7. To manufacture disc brake the following operations
are done:Turning, Cylindrical Grinding, Jig Boring,
Lapping