finite element analysis of disc brake rotor … · thermal analysis and structural analysis is done...

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International Journal of Mechanical Engineering and Technology (IJMET) Volume 7, Issue 6, November–December 2016, pp.410–416, Article ID: IJMET_07_06_039

Available online at

http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=7&IType=6

ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication

FINITE ELEMENT ANALYSIS OF DISC BRAKE

ROTOR USING DIFFERENT MATERIALS

V. Saritha

Assistant Professor, Department of Mechanical engineering,

Ellenki College of Engineering & Technology, JNTU, Hyderabad, India

Vinayak G. Kachare

M. Tech Student, Department of Mechanical Engineering,

Ellenki College of Engineering & Technology, JNTU, Hyderabad, India

ABSTRACT

In this thesis, the heat transfer rates and stresses are investigated by performing thermal

analysis and structural analysis on the disc brake rotor by using different materials. In this thesis,

comparison is done by varying materials for disc brake, Cast Iron, Carbon Fiber and Functionally

Graded Material with metal alloy Aluminum using Ceramic as interface zone will be for analysis.

FGM’s are considered for volume fractions of K=2 and K=4 Theoretical calculations are done to

calculate the material properties for each layer up to 10 layers. 3D modeling is to be done in

Pro/Engineer. Thermal analysis and Structural analysis is done in Ansys.

Key words: Disc Brake Rotor, functionally graded material (FGM), Finite Element

Cite this Article: V. Saritha and Vinayak G. Kachare, Finite Element Analysis of Disc Brake

Rotor Using Different Materials. International Journal of Mechanical Engineering and

Technology, 7(6), 2016, pp. 410–416.

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1. FUNCTIONALLY GRADED MATERIALS (FGM)

The reinforcement in composites used as structural materials in many aerospace and automobile

applications is generally distributed uniformly. Functionally graded materials (FGMs) are being used as

interfacial zone to improve the bonding strength of layered composites, to reduce the residual and thermal

stresses in bonded dissimilar materials and as wear resistant layers in machine and engine components.

They have therefore attracted considerable attention in recent years. One of the advantages of FGMs over

laminates is that there is no stress build-up at sharp material boundaries due to continuous material

property variation to eliminate potential structural integrity such as delamination.

In materials science functionally graded material (FGM) may be characterized by the variation in

composition and structure gradually over volume, resulting in corresponding changes in the properties of

the material. The materials can be designed for specific function and applications. Various approaches

based on the bulk (particulate processing), preform processing, layer processing and melt processing are

used to fabricate the functionally graded materials.

Finite Element Analysis of Disc

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2. LITERATURE SURVEY

A. Belhocine, M. Bouchetara[1]

, The objective of this study is to analyze the thermal behavior of the full

and ventilated brake discs of the vehicles using

distribution in the disc brake is used to identify all the factors and the entering parameters concerned at the

time of the braking operation, such as the type of braking, the geometric design of the di

used. The results obtained by the simulation are satisfactory compared to those of the specialized literature.

Zhang Jian, Xia Changgao[2]

, according to the real dimension of the braking disc, the finite element

modeling for three-dimensional transient cyclic symmetry during the long downhill braking is established.

The distributions of the transient temperature field of the brake disc during the braking are

variation of the friction factor combined with the temperature c

the braking are analyzed. The analysis result show: During the braking, the temperature of the brake rises

increasingly and reaches the top temperature of 316.04

temperature section concentrates in the far area of the friction surface; The changes of the friction factor is

relatively stable during the long downhill braking. There is no obvious thermal recession.

3. MODELING OF DISC BRAKE

Theoretical calculations for young’s modulus, density and thermal conductivity for

Material property calculations for

Young’s modulus

E(Z)=(Et-Eb)(z/h+1/2)ᴷ+Eb

Density

ρ(Z)=(ρt-ρb)(z/h+1/2)ᴷ+ρb

Thermal conductivity

K(Z) = (Kt-Kb)(z/h+1/2)k+Kb

4. ANALYSIS OF DISK BR

Boundary conditions

The Disk brake is analyzed for applied pressure

Structural analysis of disk brake using FGM

K=2

Finite Element Analysis of Disc Brake Rotor Using Different Materials

IJMET/index.asp 411

LITERATURE SURVEY


and ventilated brake discs of the vehicles using computing code ANSYS. The modeling of the temperature


time of the braking operation, such as the type of braking, the geometric design of the di



ensional transient cyclic symmetry during the long downhill braking is established.

distributions of the transient temperature field of the brake disc during the braking are

variation of the friction factor combined with the temperature characteristics of the friction factor during


increasingly and reaches the top temperature of 316.04K at the end of braking process, the high

ure section concentrates in the far area of the friction surface; The changes of the friction factor is


DISC BRAKE IN CREO 2.0

Figure Model of Disc Brake

calculations for young’s modulus, density and thermal conductivity for

property calculations for FGM

ANALYSIS OF DISK BRAKE

s analyzed for applied pressure 1.2MPa.

analysis of disk brake using FGM

Brake Rotor Using Different Materials

[email protected]


computing code ANSYS. The modeling of the temperature


time of the braking operation, such as the type of braking, the geometric design of the disc and the material



ensional transient cyclic symmetry during the long downhill braking is established.

distributions of the transient temperature field of the brake disc during the braking are analyzed. The

haracteristics of the friction factor during


at the end of braking process, the high

ure section concentrates in the far area of the friction surface; The changes of the friction factor is


calculations for young’s modulus, density and thermal conductivity for FGM plate


V. Saritha and Vinayak G. Kachare

IJMET/index.asp 412

Total deformation

Equivalent stress

Equivalent strain

[email protected]

Finite Element Analysis of Disc


Thermal analysis of disc brake using FGM

K=2 Layered section


IJMET/index.asp 413

brake using FGM

Temperature

Heat flux

Brake Rotor Using Different Materials

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5. RESULT & DISCUSSIONS

Structural Analysis

Material Deformation

(mm)

Stress

(N/mm2)

Strain

Cast Iron 0.0032459 4.3359 4.6655e-5

Carbon 3.986e-6 4.4455 5.9336e-8

FGM K=2 0.16157 260.45 0.00050868

K=4 0.39718 132.92 0.0022299

Thermal Analysis

Material Temperature (K) Heat Flux

(W/mm2)

Max Min

Cast Iron 353 352.88 0.00018528

Carbon Fiber 353 352.74 0.00018484

FGM K=2 358.15 291.54 7.711

K=4 357.86 291.98 7.5492

0

0.1

0.2

0.3

0.4

0.5

Cast Iron Carbon

Fiber

FGM K=2FGM K=4

DE

FO

RM

AT

ION

(m

m)

MATERIALS

COMPARISON OF DEFORMATION WITH DIFFERENT

MATERIALS

Deformation

0

50

100

150

200

250

300

Cast Iron Carbon

Fiber

FGM K=2 FGM K=4

ST

RE

SS

(N

/mm

2)

MATERIALS

COMPARISON OF STRESS WITH DIFFERENT MATERIALS

Stress



6. CONCLUSION

By observing the structural analysis results, the stresses and displacements are more for Functionally

Graded Material, than Cast Iron and Carbon Fiber. For FGM, the stresses are less at volume fraction K=4

and displacement and strain are less at K=2. By observing the thermal analysis results, the heat flux is

more when FGM is used than Cast Iron and Carbon Fiber (i.e) heat transfer rate is more for disc brake

using FGM material. Using FGM with volume fraction of K=2 is better since heat transfer rate is more. So

0.00E+00

5.00E-04

1.00E-03

1.50E-03

2.00E-03

2.50E-03

Cast Iron Carbon Fiber FGM K=2 FGM K=4

ST

RA

IN

MATERIALS

COMPARISON OF STRAIN WITH DIFFERENT MATERIALS

Strain

350

351

352

353

354

355

356

357

358

359

Cast Iron Carbon Fiber FGM K=2 FGM K=4

TE

MP

ER

AT

UR

E (

K)

MATERIALS

COMPARISON OF TEMPERATURE WITH DIFFERENT

MATERIALS

max Temp

0

2

4

6

8

10

Cast Iron Carbon

Fiber

FGM K=2 FGM K=4

HE

AT

FLU

X (

W/m

m2)

MATERIALS

COMPARISON OF HEAT FLUX WITH DIFFERENT

MATERIALS

Heat Flux



it can be concluded that using FGM with volume fraction of K=2 for disc brake since the stresses are

within the permissible limit and more heat transfer rate.

REFERENCE

[1] A. Belhocine, M. Bouchetara, Thermal behavior of full and ventilated disc brakes of vehicles, Journal of

Mechanical Science and Technology, November 2012, Volume 26, Issue 11, pp 3643–3652

[2] Zhang Jian, Xia Changga, Research of the Transient Temperature Field and Friction Properties on Disc

Brakes, Proceedings of the 2012 2nd International Conference on Computer and Information

Application (ICCIA 2012)

[3] P. Hosseini Tehrani, M.Talebi, Stress and Temperature Distribution Study in a Functionally Graded

Brake Disk, International Journal of Automotive Engineering Vol. 2, Number 3, July 2012

[4] Leszek Wawrzonek, Temperature in a disk brake, simulation and experimental verification, International

Journal of Numerical Methods for Heat & Fluid Flow, Vol. 18 Iss: 3/4, pp.387 - 400

[5] Victor Birman and Larry W. Byrd, Modeling and Analysis of Functionally Graded Materials and

Structures,

[6] S.P. Jung, T. W. Park, J H Lee, W H Kim, W. S. Chung, Finite Element Analysis of Thermoelastic

Instability of Disc Brakes, Applied Mechanics Reviews, ASME, SEPTEMBER 2007, Vol. 60

[7] Hosseini Kordkheili, S. A. and R. Naghdabadi. “Themalelastic analysis of a functionally graded rotating

disk,” Proceedings of the World Congress on Engineering 2010, Vol II, WCE 2010, June 30 - July 2,

2010, London, U.K.

[8] Zagrodzki P., "Thermoelastic instability in friction clutches and brakes –transient modal analysis

revealing mechanisms of excitation of unstable modes. ", International Journal of Solids and Structures,

Volume 46, Issues 11–12, 1 June 2009, Pages 2463–2476

[9] M.M. Shahzamanian, B.B. Sahari, M. Bayat, Z.N. Ismarrubie, F. Mustapha, Transient and thermal

contact analysis for the elastic behavior of functionally graded brake disks due to mechanical and

thermal loads, Materials and Design > 2010 > 31 > 10 > 4655-4665

[10] Voldrich J.,"Frictionally excited thermoelastic instability in disc brakes—transient problem in the full

contact regime." International Journal of Mechanical Sciences 49(2)(2):129-137 · February 2007.

[11] S. S. Deshpande, P. N. Desai, K. P. Pandey and N. P. Pangarkar , Consistent and Lumped Mass Matrices

In Dynamics and Their Impact on Finite Element Analysis Results . International Journal of

Mechanical Engineering and Technology (IJMET), 7(2), 2016, pp. 148 – 167.

[12] Rakesh Jaiswal, Anupam Raj Jha, Anush Karki, Debayan Das, Pawan Jaiswal, Saurav Rajgadia, Ankit

Basnet and Rabindra Nath Barman . Structural and Thermal Analysis of Disc Brake Using Solidworks

and Ansys , International Journal of Mechanical Engineering and Technology (IJMET) , 7 ( 1 ), 201 6 ,

pp. 67 - 77

finite element analysis of disc brake rotor … · thermal analysis and structural analysis is done...

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