final year project presentation (2)
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Thermal Analysis Investigation of Brake
Discs Using CreoFinal Year Project Presentation
Saqib Ahmed (B00238797)Supervisor – David Kennedy
Overview of Project
This project touches upon the following modules –
Computer Aided Design (CAD) Thermal and Mechanical Design Race Engineering Analysis & Simulation Design Prototyping and Testing Motorsport Design Engineering Application Project
Overview of Problem for Vauxhall VX220 Brake DiscAssumptions can be made, where the thermal and mechanical loads will cause the brake disc to
deform/fatigue/crack.
Sources Regarding ProjectAuthor Title Year Overview Method
Y. Yildiz, M. Duzgun
Stress analysis of ventilated brake discs
using the finite element method
2010Stress Analysis of ventilated disc brakes via FEM, crack
formations
Experimental & Computational (Analytical)
V.M.M Thilak, R Krishnaraj, M Sakthivel, K Kanthavel,
Deepan Marudachalam, R Palani
Transient thermal and structural analysis of the rotor disc of disc brake
2011Transient Thermal Analysis
via ANSYSComputational & Analytical
Haripal Singh, Harshdeep Shergill
Thermal Analysis of Disc Brake Using Comsol
2012
Analysis of heat dissipation/heat generation during emergency braking,
comparison of three materials (conduction, convection &
radiation)
Computational & Analytical
Ameer Fareed Basha Shaik, Ch. Lakshmi Srinivas
STRUCTURAL AND THERMAL ANALYSIS OF DISC BRAKE WITH AND
WITHOUT CROSSDRILLED ROTAR OF RACE CAR
2012Thermal Analysis using
ANSYSComputational & Analytical
K. Sowjanya, S. SureshStructural analysis of disc
brake rotor2013
Creo Parametric model of brake, using ANSYS for Von Mises stress, deflection and
normal stresses
Computational & AnalyticalMetropolitan Police Brake Test – 50mph to 0mph 50 times (http://www.fleetnews.co.uk/news/2004/11/2/fleet-in-focus-the-met/18004/)
Main Research• Modelling of Problem• Experiment • Mechanical/Thermal Loading Validation • FEA of Brake Disc Designs
Modelling of Problem
Original VX220 Modified
Experiment on Vehicle (Heat Rise)
FL FR Non-Contact
∆T (oC)Initial Temp 20.6 20.2 IR (oC)
Before After
Run 1 20.2 23.5 3.3Run 2 25.9 30.3 4.4Run 3 23.9 32.4 8.5
Ek = 1/2mv2
Ek = Q = mC∆TSince mC = constant,
∆T directly proportional to Ek
Q = mC∆T∆T = 8.5 ≈ 129171.8 J
Validation (Mechanical Clamp Force)Front Force Calculations
Pad Contact Area (mm) 46.2 mm
Effective Disc Rad (mm) 120.9 mm
0.1209 m
Clamp Force, F 12688 NPer Side of Brake
Disc 6343.8 N
• Corner weights Calculated• 65-35 Front-Rear Brake
Balance• Disc Dia – 288 mm
Area 1 = 11145.5mmArea 2 = 14537.0mm
Area of Webbing = 3391.5mm
Validation (Mechanical Clamp Force)
10% Leigh-way for FEAStress found on model –
3.7744MPa
Hand Calculations
Validation (Thermal Stress Analysis)
Cast iron 4.5% C, ASTM A-48
Yield Strength = 130MPa
Ultimate Tensile Strength = 200 MPaOriginal VX220 Modifie
d
Validation (Thermal Stress Analysis)
OriginalMaxStress = 2738 MPa
Realistic = 1643MPa
VX220MaxStress = 1212.18
MPaRealistic = 727.317 MPa
ModifiedMaxStress = 1305.11MPa
Realistic = 783.072 MPa
FE Analysis of Brake Discs
Mechanical plus Thermal Load Cases
Consider the bolt holes added to the model since this will allow the model to be free to rotate around in the z-axis
Angular Velocity and Acceleration calculation required
Consider the scaling of results (very important!)
Problems and Limitations of Project
Working out exact values for the analysis Centre of Gravity of vehicle Exact calibration of the heat gun
Limitations with CAD/FEA Software no underlying shells or beams in the mechanical & thermal analysis Fine details aborting analysis on Creo Simulate
Discussion & Conclusion
Discussion To be completed - Timeline of Project Assumptions from Thermal & Mechanical Analysis
Conclusion• Modelling of Problem• Experiment • Mechanical/Thermal Loading Validation • FEA of Brake Disc Designs
Future Research
Choice of materials (isotopes) Centre of Gravity of Vehicle Experiment (knife-edge) Implementing dimensional analysis Using a different FEA software which is more suitable (Comsol,
ANYSYS, ABAQUS CAE) More demanding physical test (Metropolitan Police) Physical modelling of modified brake design in controlled conditions Manufacturing methods and heat treatment to components
Thank you for listening!
Any Questions?
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