International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 04 Issue: 07 | July -2017
p-ISSN: 2395-0072
www.irjet.net
Structural Analysis of Disc Brake Rotor for Different Materials Harshal Suresh Shinde1 1PG
Student, Department of Mechanical Engineering, S. V. C. E. T., Rajuri, Pune ---------------------------------------------------------------------***--------------------------------------------------------------------2. LITERATURE SURVEY Abstract - In this paper we are going to find the temperature on surface of disc brake rotor for different materials, to find the best suitable alternative material for disc brake rotor. We have performed experimentation on disc brake rotor to obtain the temperature on surface of disc rotor for five different material which are Aluminium, Aluminium-Copper Alloy, Titanium - 2, Titanium – 5 & Grey Cast Iron. The temperature on surface of disc rotor on outer periphery is obtained from the actual test setup for the disc brake rotor. This test is carried out for 5 minutes running with the desired condition & then suddenly applying the desired load. Also mathematical model is prepared to calculate the heat flux generated by theoretically. Actual weights of all materials were measured and the mechanical properties such as compressive strength, wear rate and coefficient of friction of material were compared. Then disc rotor is analyzed for temperature profile & total heat flux generated by using Ansys-17 and at final the analysis results are compared with experimental results to find out the best suitable alternative material other than Grey Cast Iron.
M.A. Maleque[12] have been study about the brake rotor material selection method and select the optimum material for the application of brake disc system emphasizing on the substitution of this cast iron by any other lightweight material. Two methods are introduced for the selection of materials, such as cost per unit property and digital logic methods. Material performance requirements were analysed and alternative solutions were evaluated among cast iron, aluminium alloy, titanium alloy, ceramics and composites. He has been considered Mechanical properties including compressive strength, friction coefficient, wear resistance, thermal conductivity and specific gravity as well as cost, were used as the key parameters in the material selection stages. The analysis led to AMC 2 material and identified as an optimum material among the candidate materials for brake disc. This could be justifiable in this case as higher friction coefficient and lower density are advantageous from the technical and economical point of view for this type of application. Faramarz Talati[13] have been study the governing heat equations for the disk and the pad are extracted in the form of transient heat equations with heat generation that is dependant to time and space. In the derivation of the heat equations, parameters such as the duration of braking, vehicle velocity, geometries and the dimensions of the brake components, materials of the disk brake rotor and the pad and contact pressure distribution have been taken into account. The problem is solved analytically using Green’s function approach. It is concluded that the heat generated due to friction between the disk and the pad should be ideally dissipated to the environment to avoid decreasing the friction coefficient between the disk and the pad and to avoid the temperature rise of various brake components and brake fluid vaporization due to excessive heating. Susmitha Sankatala[3] have been study about Friction causes between 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 paper is to model a disc brake used in Honda Civic. Structural and Thermal is done on the disc brake. The materials used are Stainless Steel, Cast Iron and Aluminium Alloy. Analysis is also done by changing the design of disc brake. Actual disc
Key Words: Disc Brake Rotor, Temperature analysis, Weight Reduction, Transient Analysis
1. INTRODUCTION The brake disc is usually made of cast iron, but may in some cases be made of composites such as reinforced carbon–carbon or ceramic matrix composites. This is connected to the wheel and/or the axle. To retard 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. Discs may also be slotted, where shallow channels are machined into the disc to aid in removing dust and gas. Slotting is the preferred method in most racing environments to remove gas and water and to deglaze brake pads. Some discs are both drilled and slotted. Slotted discs are generally not used on standard vehicles because they quickly wear down brake pads; however, this removal of material is beneficial to race vehicles since it keeps the pads soft and avoids vitrification of their surfaces. As a way of avoiding thermal stress, cracking and warping, the disc is sometimes mounted in a half loose way to the hub with coarse splines. This allows the disc to expand in a controlled symmetrical way and with less unwanted heat transfer to the hub.
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