Design and Analysis of Brake Component
Akshat Ruhela1 , Aayush Srivastava2
1,2 Student, Department of Mechanical Engineering, ABES Engineering College, Uttar Pradesh, India *** Abstract - Theperformanceandsuccessofanyvehicledependontheabilityofitscomponentstofunctionproperlyunderany conditionssuchaswettrack,drytrack,andoff roadterrains.Theperformanceofthevehiclecanfurtherbeimprovedby making the components more robust along with the proper reduction in their weight. The safe operation of any vehicle requiresconstantadjustmentsofitsspeedunderchangingtrafficconditionsandthebrakediscisanimportantcomponentfor thedecelerationandmaintainingthespeedofavehicleundercontrolwhichincludesstopping.Thisresearchpaperstudiesan optimized design of the brake disc which aims at reducing weight and maintaining the strength along with reducing the deformationathighertemperaturesascomparedtotheOEMavailableinthemarket.Thebrakediscisbeingmodelledin SOLIDWORKSandanalysedviaFEAinANSYSforstaticandthermalloads
1. INTRODUCTION
Brakeisacomponentusedtodeaccelerateavehicle.MaincomponentsofbrakeareBrakepedal,mastercylinder,hydraulic pressuresensors,thebrakehoses,hydrauliccontrolunit(ECU),caliperanddisk. Brakepedaldesigningplaysaveryimportant factorintheforceanalysisofmastercylinderasthereisalwaysaspaceconstraintindesigninganATVresulting,thatdriver willnotabletoapplyforceonpedalsuchthatonregularvehicles.Duringbrakepedaldesignspaceconstraintandresting positionofadrivershouldbecomfortableforapplyingforcesufficienttodrivemastercylindertoitsfullstroke.
2. LITERATURE REVIEW
• [1]K.Sowjanya,S.Suresh,“StructuralAnalysisofDiscBrakeRotor”,InternationalJournalofComputerTrendsand Technology(IJCTT),Vol.4Issue7 July2013
• [2]NeerajSingh,R.S.Bharj,KamalKumar,“OptimumDesignandExperimentalAnalysisofBrakeSystemforBAJAATV”, InternationalJournalofResearchinManagement,Science&Technology(E ISSN:2321 3264)Vol.5,No.3,December 17”.
• [3]VivekSinghNegi,NayanDeshmukh,AmitDeshpande,“DesignandAnalysisofBrakesystem”,InternationalJournal ofAdvanceEngineeringandResearchDevelopmentVol 4(11),November 2017”.
• [4]Kush Soni, Gaurang Vara, Ishit Sheth, Harshil Patel, “Design and Analysis of Braking System for ISIE ESVC”, InternationalJournalofAppliedEngineeringResearchISSN0973 4562Vol 13,Number10(2018)pp.8572 8576”.
• [5]KKDhande,NIJamadarandSandeepGhatge July2014 “DESIGNANDANALYSISOFCOMPOSITEBRAKEPEDAL: AN ERGONOMIC APPROACH”, International Journal of Mechanical Engineering and Robotics Research (IJMERR), Volume3(3),pp.474 482.
• [6] Nand Mangukia and Nandish Mangukia 2018 “Design and Fabrication of Brake Pedal for All Terrain Vehicle “,INTERNATIONALJOURNALOFENGINEERINGDEVELOPMENTANDRESEARCH (IJEDR),Volume6(2),pp.562 568.
• [7] Miss. ASHWINI N.GAWANDE, Prof.G.E.KONDHALKAR, and Prof. ASHISH R.PAWAR , May 2017 “STATIC STRUCTURALANALYSISANDOPTIMIZATIONOFBRAKEPEDAL”,InternationalResearchJournalofEngineeringand Technology(IRJET),Volume:04(5),pp.3222 3227.
3. METHODOLOGY
Thisstudyiscompletedin2parts.Firstpartcoversthemodellingandanalysisofstressgeneratedinthecomponent,second partcoversthestudyofstressesandoptimisationofthebrakepedalthroughtheconceptofbiomimicry.CADmodelofthe brakepedalisdevelopedinSolidworksandtheFEAanalysishasbeencarriedoutinANSYSWorkbench2019R1.
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Initial calculations and design considerations.
CAD Modelling (Creo parametric 5.0)
FEA Analysis (ANSYS Workbench 2019 R1)
YES NO Yes
Study of stresses generated
Optimisation of CAD Model Again FEA Analysis (ANSYS Workbench 2019 R1)
Design Evaluation Design Evaluation Final result and finish
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t= t=0.96sec
Calculation for weight distribution and required braking force
RF =W×(a+coefficientoffriction*h)×cos( ) =2452.5× RF =1858.13N
MASS ON FRONT AXLE DURING DYNAMIC CONDITION
= = 189.41kg
Masstransferonfrontaxleduringbraking=189.41kg
Frontbrakingforcerequiredforfrontaxle= 189.41×17.34=3284.36N
Forcerequiredforeachwheel= =1642.18N
Torquerequiredforeachwheel= FFrontwheel ×Wheelradius = 1642.18 241.3 =396.25Nm
T Frontwheel=TFrontrotor
T Frontwheel =F rotor rotorradius FRotor = = Frotor =3635.32N
5. MATERIAL SELECTION
Thebrakepedalsaremadefromdifferentmaterialssuchcastiron,aluminium,andmildsteel.Adetailedstudywascarriedout toselect themostsuitable material dependingonthefactorssuchasavailabilityof material,Yieldstrength, weight,cost, weldability.AL 7075T6wasselectedoverGreybasedonavailability,cost,Yieldstrengthandfatiguestrength.
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6. DESIGN: CAD MODELLING
TheinitialCADmodelofthebrakepedalhasbeencreatedinSolidworks2019.Itconsistsofmountingpointsforitselfand2 mastercylinders.Thedesignprocesseswerestartedwithdefiningandevaluatingallthedesignconstraints.
Fig1: ModelOfDiscBrake
7. MESHING
TheCADmodelisimportedintoANSYSWorkbench2019R1.Theautomaticmeshwithsize1mmisusedforthisstudy. Nodes 134283 Elements 73230
Fig 2:MeshModel
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ANALYSIS
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9. DESIGN: INITIAL CAD MODELLING: Brake Pedal
TheinitialCADmodelofthebrakepedalhasbeencreatedinPTCCreoParametric5.0.Itconsistsofmountingpointsforitself and2mastercylinders.Thedesignprocesseswerestartedwithdefiningandevaluatingallthedesignconstraints.Themodeof manufacturingforthisbrakepedalisweldingoflasercutparts.Thegeometryalsoincludesfilletsof4mmaroundthefootrest andpivotregiontorepresentweldbead.InitialCADmodelofthebrakepedalis
Nodes 134283 Elements 73230
Boundaryconditions:
Aof2000Nisappliednormallybydriverin xaxisonthefootrest.
Thepivotpointisfixed.
Forceof45Nisappliedin xaxistosimulatetheforcepresentedbymastercylinders.
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Study of generated stresses:
Thesecondpartofthisresearchincludestheoptimisationofbrakepedaltominimisetheweightofthecomponentandto remove extra material.Theinspirationforoptimisationwasdrawnfroma honeycombstructure.Ahoneycomb structure providesrigidityandefficientstressdistributionalongwithminimalweight.
Thevon Misesstressesandsafetyfactorobtainedfromtheanalysisareusedtomaptheregionwheretheoptimisationstudy canbecarriedoutinordertoremoveextramaterial.TheregionwheretheoptimisationstudyisneededisshowninFig*.The Redregiondefinesthedesignspacewheretheoptimisationstudyiscarriedout;thestressesinthisregion arelowwhich
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contributestohighsafetyfactorwhichinturnmeansthatthereisexcessmaterialavailableinthisregion.Theyellowregion enclosesthespacewherehighstressesarebeinggeneratedthusnooptimisationstudyisrequiredinthisregion.
DESIGN: OPTIMISATION CAD MODELLING
TheoptimisedCADmodelofthebrakepedalhasbeencreatedinPTCCreoParametric5.0.Itconsistsofmountingpointsfor itselfand2mastercylinders.TheDesignspacehasbeenoptimisedwithahexagonallatticestructureforweightreduction. OptimisedCADmodelofthebrakepedalisshowninFig*\
ANALYSIS:
The Mesh and boundary conditions are kept same for the second analysis.
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Results:
MaximumEquivalentvon MisesStress=363Mpa
MinimumSafetyFactor=1.02
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10. CONCLUSION
1.Uponcomparisonitwasobservedthatthedesign2ofGenerativedesignModelhasthehighestfactorofsafetyforsimilar working conditionsi.e."2.6257" and weight of the brake pedal was reduced from "256 grams" to "122 grams" which is "52.34%"weightreduction.
2.Allstressesareunderallowablestressinstructuralanalysis.
3.Fromthesetofvalues,thebestoutcomesarefoundatdeformationis0.014503mm,stress 92.09MPaandtemperatureat 93.296ConAL-7075T6with5mmthickness
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11. REFERENCES
[1]K KDhande,N I JamadarandSandeepGhatge July 2014 “DESIGN AND ANALYSIS OF COMPOSITE BRAKE PEDAL: AN ERGONOMIC APPROACH”, International Journal of Mechanical Engineering and Robotics Research (IJMERR),Volume3(3),pp. 474 482.
[2] Nand Mangukia and Nandish Mangukia 2018 “Design and Fabrication of Brake Pedal for All Terrain Vehicle “,INTERNATIONALJOURNALOFENGINEERINGDEVELOPMENTANDRESEARCH (IJEDR),Volume6(2),pp.562 568.
[3] Miss. ASHWINI N.GAWANDE, Prof.G.E.KONDHALKAR, and Prof. ASHISH R.PAWAR , May 2017 “STATIC STRUCTURAL ANALYSIS AND OPTIMIZATION OF BRAKE PEDAL”,InternationalResearchJournalofEngineeringandTechnology(IRJET), Volume:04(5),pp.3222 3227.
[4] MIM Sargini , SH Masood , Suresh Palanisamy , Elammaran Jayamani and Ajay Kapoor , “Finite element analysis of automotive arm brake pedal for rapidmanufacturing”, IOP Conference Series: Materials Science and Engineering, doi:10.1088/1757 899X/715/1/012020.
[5]Degenstein,Thomas,Winner,Hermann,“DynamicMeasurementoftheForcesintheFrictionAreaofaDiscBrakeduringa Brakingprocess”,Vol.2,pp.19,2006.
[2]AkshatSharma,AmitKumarMarwah,“BrakingSystems:Past,Present&Future”,Vol.2,Issue 3,pp.29 31,March 2013 ISSN 2250 1991
[3]K.Sowjanya,S.Suresh,“StructuralAnalysisofDiscBrakeRotor”,InternationalJournalofComputerTrendsandTechnology (IJCTT),Vol.4Issue7 July2013
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