THERMO ELASTIC AND STRESS ANALYSIS OF DISC BRAKE

A PROJECT REPORT Submitted by ELANGO.N VIGNESHKUMARAN.C ARAVINDKUMAR.N (090111139011) (090111139053) (100411139001)

In partial fulfillment for the award of degree of

BACHELOR OF ENGINEERING
in MECHANICAL ENGINEERING

P.A. COLLEGE OF ENGINEERING AND TECHNOLOGY, POLLACHI.

ANNA UNIVERSITY, CHENNAI 600 025

APRIL 2012

ANNA UNIVERSITY, CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report THERMO ELASTIC AND STRESS ANALYSIS OF DISC BRAKE is the bonafide work of N. ELANGO
(09011139011), C.VIGNESHKUMARAN(09011139053), N.ARAVINDKUMAR (100411139001) who carried out the project work under my supervision.

SIGNATURE SUPERVISOR Prof. T. VARUNKUMAR Assistant professor, Department of Mechanical Engg., P.A. College of Engg. & Technology, Pollachi 642002.
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SIGNATURE HEAD OF THE DEPARTMENT Dr. V. RAMALINGHAM Dean / Head of the department, Department of Mechanical Engg, P.A. College of Engg. & Technology, Pollachi 642002.

ACKNOWLEDGEMENT Our sincere thanks to our respected chairman and chairperson for their encouragement towards our project activities and providing necessary accessories. We express our sincere gratitude to Dr.T.Manikandan, Principal and Dr.V.Ramalingam, Dean cum Head of Department, Department of Mechanical Engineering, P.A College of Engineering and Technology, Pollachi for providing the available resources in the college. We have a great pleasure in expressing our sincere gratitude for the valuable suggestions to our guide Mr. T. Varunkumar, Assistant Professor of Mechanical Engineering. Our special thanks to Mr. N. Manikandan, Mechanical Department for the valuable suggestions in completing the project successfully. We would like to thank all our staff members and lab technicians for giving valuable guidance to our project. Our special thanks to our classmates for their enthusiastic attitude and calming influence.

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CONTENTS
CH. NO
Acknowledgement List of figures List of table Abstract

TITLE

PAGE NO
iii vi vii viii 1-4 1 1 2 3 3 4 4 5-7 8 - 15 8 8 9 9 9 9 10 11 11 11

INTRODUCTION 1.1 Introduction 1.2 Classification 1.3 Disc brake 1.3.1 Floating Caliper Type 1.3.2 Fixed Caliper Type 1.4 Problems in Disc brake 1.5 Objective of the present Study

2 3

LITERATURE REVIEW FINITE ELEMENT ANALYSIS 3.1 Introduction 3.2 Procedure for ANSYS analysis 3.2.1 Build the model 3.2.2 Material Properties 3.2.3 Solution a. Pre processor b. Element Type c. Homogeneous structure d. Layered structure solid e. Geometric Definition
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f. Model Generation g. Mesh Generation h. Finite Element Generation i. j. Boundary conditions & loading Model display

11 11 12 12 12 12 13 13 14 14 14 14 15 15 16 - 20 17 17 18 20 21 - 23 21 21 21 22 22 23 30 - 33 34

k. Material defection l. Solution

m. Post processor 3.3 Thermal analysis 3.3.1 Types of thermal Analysis 3.3.2 Planning the Analysis 3.4 Structural analysis 3.4.1 Types of thermal Analysis 3.4.2 Planning the Analysis 4 MODELING AND ANALYSIS 4.1 Definition of problem domain 4.2 Dimension of disc brake 4.3 Finite element mesh 4.4 Solution

RESULT AND DISCUSSION 5.1 Validation of result 5.2 Materials analyzed 5.2.1 Cast iron 5.2.2 Stainless Steel 5.2.3 Alumina 5.2.4 E-Glass Fiber

6 7

CONCLUSION REFERENCES

LIST OF FIGURES AND TABLES LIST OF FIGURES

FIG. NO 1.1 1.2 1.3 4.1 4.2 4.3 4.4 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 6.1 6.2 6.3 Disc brake assembly Floating caliper disc brake Fixed caliper disc brake Dimensions of disc brake model Imported model of disc Meshed model Loaded model of the disc brake Von Mises stress distribution in cast iron disk Von Mises stress distribution in stainless steel disk Von Mises stress distribution in alumina disk Von Mises stress distribution E-glass fiber disk Elastic strain in cast iron disk Elastic strain in stainless steel disk Elastic strain in alumina disk Elastic strain in E-glass fiber disk Average displacement in cast iron disk Average displacement in stainless steel disk Average displacement in alumina disk Average displacement in E-glass fiber disk Graph Comparison for stress values Graph Comparison for strain values Graph Comparison for displacement values DESCRIPTION PAGE NO 2 3 3 17 18 19 19 24 24 25 25 26 26 27 27 28 28 29 29 31 31 32

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LIST OF TABLES
TABLE NO 3.1 5.1 5.2 5.3 5.4 5.5 Steps used in ANSYS Material properties of Cast iron Material properties of Stainless Steel Material properties of Alumina Material properties of E- Glass fiber Comparison DESCRIPTION PAGE NO 10 22 22 23 23 32

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ABSTRACT
Transient Thermal and Structural Analysis of the Rotor Disc of Disk Brake is aimed at evaluating the performance of disc brake rotor of a car under severe braking conditions and there by assist in disc rotor design and analysis. An investigation into usage of new materials is required which improve braking efficiency and provide greater stability to vehicle. This investigation can be done using ANSYS software. ANSYS 13.0 is a dedicated finite element package used for determining the temperature distribution, variation of the stresses and deformation across the disc brake profile. In the present work, an attempt has been made to investigate the suitable hybrid aluminum based material which is lighter than stainless steel and has good Youngs modulus, Yield strength and density properties. Aluminum base metal matrix composite have a promising friction and wear behavior as a Disk brake rotor. The transient thermo elastic analysis of Disc brakes in severe braking condition has been performed and the results were going to be compared. And also thermo elastic instability (TIE) phenomenon (the unstable growth of contact pressure) is going to be investigated in the present study, and the influence of the material properties on the thermo elastic behaviors (the maximum temperature on the friction surfaces) is stability is assured. calculated to facilitate the conceptual design of the disk brake system. By identifying the true design features, the extended service life and long term

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CHAPTER -1 INTRODUCTION
1.1 INTRODUCTION
A brake is a device by means of which artificial frictional resistance is applied to moving machine member, in order to stop the motion of a machine. In the process of performing this function, the brakes absorb either kinetic energy of the moving member or the potential energy given up by objects being lowered by hoists, elevators etc. The energy absorbed by brakes is dissipated in the form of heat. This heat is dissipated in the surrounding atmosphere to stop the vehicle, so the brake system should have following requirements: The brakes must be strong enough to stop the vehicle with in a minimum distance in an emergency. The driver must have proper control over the vehicle during braking and vehicle must not skid. The brakes must have well anti fade characteristics i.e. their effectiveness should not decrease with constant prolonged application. The brakes should have anti wear properties.

1.2

CLASSIFICATION
The mechanical brakes according to the direction of acting force may be divided into

the following two groups: Radial brakes In these brakes the force acting on the brakes drum is in radial direction. The radial brakes may be subdivided into external brakes and internal brakes. Axial Brakes In these brakes the force acting on the brake drum is only in the axial direction. i.e. Disk brakes, Cone brakes. Radial Brake Axial Brake

1.3

DISK BRAKE
A disk brake consists of a stainless steel disk bolted to the wheel hub and a stationary

housing called caliper. The caliper is connected to some stationary part of the vehicle like the axle casing or the stub axle as is cast in two parts each part containing a piston. In between each piston and the disk there is a friction pad held in position by retaining pins, spring plates etc. passages are drilled in the caliper for the fluid to enter or leave each housing. The passages are also connected to another one for bleeding. Each cylinder contains rubber-sealing ring between the cylinder and piston. A schematic diagram is shown in the figure 1.1.

Figure 1.1 Disc Brake Assembly The main components of the disc brake are: The Brake Pads The Caliper which contains the piston The Rotor, which is mounted to the hub

When the brakes are applied, hydraulically actuated pistons move the friction pads in to contact with the rotating disk, applying equal and opposite forces on the disk. Due to the friction in between disk and pad surfaces, the kinetic energy of the rotating wheel is converted into heat, and stop after a certain distance. On releasing the brakes the brakes the rubber-sealing ring acts as return spring and retract the pistons and the friction pads away from the disk.
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1.3.1 Floating Caliper Type The floating caliper design is not only more economical and lighter weight but also requires fewer parts than its fixed caliper counterpart. Depending on the application, the floating caliper has either one or two pistons.

Figure 1.2 Floating Caliper Disc Brake The piston is located in one side of the caliper only. Hydraulic pressure from the master cylinder is applied to piston (A) and thus presses the inner pad against the disc rotor. At the same time, an equal hydraulic pressure (reaction force B) acts on the bottom of the cylinder. This causes the caliper to move to the right, and presses the outer pad located opposite the piston against the disc rotor. The piston exerts pressure on the inside pad as well as moving the caliper body to engage the outside pad. 1.3.2 Fixed Caliper Type

Figure 1.3 Fixed Caliper Disc Brake The fixed caliper design has pistons located on both sides of the caliper providing equal force to each pad. The caliper configuration can incorporate one or two pistons on each side.
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The ability to include multiple pistons provides for greater braking force and a compact design. Because these assemblies are larger and heavier than the floating caliper, they absorb and dissipate more heat. This design is able to withstand a greater number of repeated hard stops without brake fade. This design is found on models which include larger engine displacement such as the V-6 Camry and Avalon as well as the Supra and four-wheel-drive Truck, T100 and Tacoma.

1.4

PROBLEMS IN DISK BRAKE

In the course of brake operation, frictional heat is dissipated mostly into pads and a disk,

and an occasional uneven temperature distribution on the components could induce severe thermo elastic distortion of the disk. The thermal distortion of a normally flat surface into a highly deformed state, called thermo elastic transition. At other times, however, the stable evolution behavior of the sliding system crosses a threshold whereupon a sudden change of contact conditions occurs as the result of instability. This invokes a feedback loop that comprises the localized elevation of frictional heating, the resultant localized bulging, a localized pressure increases as the result of bulging, and further elevation of frictional heating as the result of the pressure increase. When this process leads to an accelerated change of contact pressure distribution, the unexpected hot roughness of thermal distortion may as thermo elastic instability (TEI). The thermo elastic instability phenomenon occurs more easily as the rotating speed of the disk increases. This region where the contact load is concentrated reaches very high temperatures, which cause deterioration in braking performance. Moreover, in the course of their presence on the disk, the passage of thermally distorted hot spots moving under the brake pads causes low-frequency brake vibration. grow unstably under some conditions, resulting in local hot spots and leaving thermal cracks on the disk. This is known

1.5

OBJECTIVE OF THE PRESENT STUDY

The given disk brake rotor of its stability and rigidity (for this Thermal analysis and coupled structural analysis is carried out on a given disk brake rotor. Best combination of parameters of disk brake rotor like Flange width, Wall thickness and material there by a best combination is suggested.

The present investigation is aimed to study:

CHAPTER - 2 LITERATURE REVIEW

In order to study the transient thermo elastic behavior of the disk brake , the literature related to the thermo elastic analysis of clutch, two sliding surfaces and brakes have been studied. Since in the past most of the studies of brake and clutch is carried out for thermo elastic analysis by considering it as a case of two dimensional. The following section details the literature available and relevant to the proposed study of transient thermo elastic analysis of a solid disk brake, as a case of three dimensional. F.E. Kennedy et al [1] developed the numerical and experimental methods applied to tribology. He improved the techniques for finite element analysis of sliding surface temperature. Essential component of manually operated vehicle transmission is the synchronizer. Synchronizers have the task of minimizing the speed difference between the shifted gearwheel and the shaft by means of frictional torque before engaging the gear. Proper operation requires a sufficiently high coefficient of friction. It is common practice to investigate the friction and wear behavior under various loading conditions on test rigs or in vehicle tests. An optimized design of the system with regard to appropriate function and durability on the one hand as well as low cost, low mass and compact over- all dimensions on the other hand requires extensive testing. According to the present state of knowledge, derived from numerous experimental investigations, temperature can be attributed the most significant influence on the tribology of synchronizing systems. Therefore, the influence of various loading conditions on contact temperature was investigated; and tribological performance a relation between temperature was established. The Finite Element Method was applied to

simulate the thermal behavior of a synchronizing system depending on different operating conditions. Characteristics o f t h e tribological performance of the molybdenum coated synchromesh ring in contact with a steel cone were derived from extensive experimental investigations. Significantly different friction and wear patterns can be distinguished. At heavy loading conditions the coefficient of friction is quite high and continuously severe wear occurs; light operating conditions results in a low friction coefficient, whilst no more wear is observed. Between those two extremes an indifferent regime exists, in which both patterns of tribological behavior occur. A reason for this characteristics behavior of the system described here was found by means of the Finite Element simulation. Apparently, the friction and
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wear pattern

depends on the temperature in the contact area; for mild wear and the low friction co efficient the contact temperature must not exceed a critical value in order to avoid severe wear. Within limits the predicted tribological behavior and the test results are in good agreement. The calculation of the temperature in the contact area provides a basis for a classification of the load conditions in terms of their thermal and tribological effect, a practically applicable estimation of service life and a design procedure based on numerical simulation rather than on testing. J.Y.Lin et al Radial transient heat conduction in composite hollow cylinders with the temperature-dependent thermal conductivity was investigated numerically by using an application of the Laplace transform technique combined with the finite element method (FEM) or with the finite difference method (FDM). The domain of the governing equation was discretized using the FEM or FDM. The nonlinear terms were linear zed by Taylor's series approximation. The time-derivatives in the linear zed equations were transformed to the corresponding algebraic terms by the application of the Laplace transform. The numerical inversion of the Laplace transform was applied to invert the transformed temperatures to the temperatures in the physical quantity. Since the present method was not a time-stepping procedure, the results at a specific time can be calculated in the time domain without any stepby-step computations. To show the accuracy of the present method for the problems under consideration, a comparison of the hybrid finite element solutions with the hybrid finite difference solutions was made. J. Brilla et al [3] generalized variational principles in the sense of the Laplace transform for viscoelasti problems were derived. Then mathematical theory of viscoelasticity in generalized Hardy spaces and in weighted anisotropic Sobolevspaces and spectral theory of corresponding non-self adjoint operators was elaborated. Finally the Laplace transform FEM for numerical analysis of time-dependent problems of the mathematical physics was proposed and analyzed. S. V. Tsinopoulos et al [4] an advanced boundary element method was appropriately combined with the fast Fourier transform (FFT) to analyze general axisymmetric problems in frequency domain elastodynamics. The problems were characterized by axisymmetric geometry and non-axisymmetric boundary conditions. Boundary quantities were expanded in complex Fourier series in the circumferential direction and the problem was
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efficiently decomposed into a series of problems, which were solved by the BEM for the Fourier boundary quantities, discretizing the surface generator of the axisymmetric body. Quadratic boundary elements were used and BEM integrations were done by FFT algorithm in the circumferential direction and by Gauss quadrature in the generator direction. Singular integrals were evaluated directly in a highly accurate way. The Fourier transformed solution was then numerically inverted by the FFT provided the final solut i on . The method combines high accuracy and efficiency and this was demonstrated illustrative numerical examples. H. C. Wang et al [5] a new numerical method was proposed for the boundary element analysis of axisymmetric bodies. The method was based on complex Fourier series expansion of boundary quantities in circumferential direction, which reduces the boundary element equation to an integral equation in (r-z) plane involving the Fourier coefficients of boundary quantities, where r and z are the co-ordinates of the (r, , z) cylindrical co-ordinate system. The kernels appearing in these integral equations can be computed effectively by discrete Fourier transform formulas together with the fast Fourier transform (FFT) algorithm, and the integral equations in (r-z) plane can be solved by Gaussian quadrature, which establishes the Fourier coefficients associated with boundary quantities. The Fourier transform solution can then be inverted into (r, , and z) space by using again discrete Fourier transform formulas together with FFT algorithm. In the study, first we presented the formulation of the proposed method which was outlined above. Then, the method was assessed by using three sample problems. A good agreement was observed in the comparisons of the predictions of the method with those available in the literature. It was further found that the proposed method provided considerable saving in computer time compared to existing methods.

CHAPTER -3 FINITE ELEMENT ANALYSIS

3.1 INTRODUCTION
The finite element method is numerical analysis technique for obtaining approximate solutions to a wide variety of engineering problems. Because of its diversity and flexibility as an analysis tool, it is receiving much attention in almost every industry. In more and more engineering situations today, we find that it is necessary to obtain approximate solutions to problem rather than exact closed form solution. It is not possible to obtain analytical mathematical solutions for many engineering problems. An analytical solutions is a mathematical expression that gives the values of the desired unknown quantity at any location in the body, as consequence it is valid for infinite number of location in the body. For problems involving complex material properties and boundary conditions, the engineer resorts to numerical methods that provide approximate, but acceptable solutions. The finite element method has become a powerful tool for the numerical solutions of a wide range of engineering problems. It has been developed simultaneously with the increasing use of the high- speed electronic digital computers and with the growing emphasis on numerical methods for engineering analysis. This method started as a generalization of the structural idea to some problems of elastic continuum problem, started in terms of different equations.

3.2

PROCEDURE FOR ANSYS ANALYSIS

Static analysis is used to determine the displacements stresses, stains and forces in

structures or components due to loads that do not induce significant inertia and damping effects. Steady loading in response conditions are assumed. The kinds of loading that can be applied in a static analysis include externally applied forces and pressures, steady state inertial forces such as gravity or rotational velocity In our imposed present (non-zero) work we displacements, temperatures (for thermal strain). A static analysis can be either linear or non linear. consider linear static analysis.

The procedure for static analysis consists of these main steps Building the model Obtaining the solution Reviewing the results.

3.2.1 BUILD THE MODEL

In this step we specify the job name and analysis title use PREP7 to define the element types, element real constants, material properties and model geometry element type both linear and non- linear structural elements are allowed. The ANSYS elements library contains over 80 different element types. A unique number and prefix identify each element type. E.g. BEAM 94, PLANE 71, SOLID 96 and PIPE 16

3.2.2 MATERIAL PROPERTIES

Youngs modulus (EX) must be defined for a static analysis. If we plan to apply inertia loads (such as gravity) we define mass properties such as density (DENS). Similarly if we plan to apply thermal loads (temperatures) we define coefficient of thermal expansion (ALPX).

3.2.3

SOLUTION
In this step we define the analysis type and options, apply loads and initiate the finite

element solution. This involves three phases: Pre-processor phase a. Pre-processor Pre processor has been developed so that the same program is available on micro, mini, super-mini and mainframe computer system. This slows easy transfer of models one system to other. Solution phase Post-processor phase

Table 3.1 Steps used in ANSYS PREPROCESSOR PHASE GEOMETRY DEFINITONS MESH GENERATION MATERIAL DEFINITIONS CONSTRAINT DEFINITIONS LOAD DEFINITION MODEL DISPLAY DISPLACEMENT, STRESS, ETC. CALCULATION SOLUTION PHASE ELEMENTMATRIX FORMULATION OVERALL MATRIX TRIANGULARIZATION (WAVE FRONT) POST-PROCESSOR PHASE POST SOLUTION OPERATIONS POST DATA PRINT OUT (FOR REPORTS) POST DATA SCANNING POST DATA DISPLAY

Pre processor is an interactive model builder to prepare the FE (finite element) model and input data. The solution phase utilizes the input data developed by the pre processor, and prepares the solution according to the problem definition. It creates input files to the temperature etc. on the screen in the form of contours. b. Element type SOLID185 is used for 3-D modeling of solid structures. It is defined by eight nodes having three degrees of freedom at each node: translations in the nodal x, y, and z directions. The element has plasticity, hyper elasticity, stress stiffening, creep, large deflection, and large strain capabilities. It also has mixed formulation capability for simulating deformations of nearly incompressible elasto plastic materials, and fully incompressible hyper elastic materials. SOLID185 is available in two forms:

Homogeneous Structural Solid (KEYOPT(3) = 0, the default) Layered Structural Solid (KEYOPT(3) = 1)
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c. Homogeneous Structure SOLID185 Structural Solid is suitable for modeling general 3-D solid structures. It allows for prism and tetrahedral degenerations when used in irregular regions. Various element technologies such as B-bar, uniformly reduced integration, and enhanced strains are supported. d. Layered structure solid SOLID185 Layered Solid to model layered thick shells or solids. The layered section definition is given by ANSYS section (SECxxx) commands. A prism degeneration option is also available. e. Geometric Definitions There are four different geometric entities in pre processor namely key points, lines, area and volumes. These entities can be used to obtain the geometric representation of the structure. All the entities are independent of other and have unique identification labels. f. Model Generations Two different methods are used to generate a model: Direct generation. Solid modeling

With solid modeling we can describe the geometric boundaries of the model, establish controls over the size and desired shape of the elements and then instruct ANSYS program to generate all the nodes and elements automatically. Although, some automatic data generation is possible (by using commands such as FILL, NGEN, EGEN etc) the direct generation method essentially a hands on numerical method that requires us to keep track of all the node numbers as we develop the finite element mesh. This detailed book keeping can become difficult for large models, giving scope for modeling errors. Solid modeling is usually more powerful and versatile than direct generation and is commonly preferred method of generating a model. g. Mesh generation In the finite element analysis the basic concept is to analyze the structure, which is an assemblage of discrete pieces called elements, which are connected, together at a finite number of points called Nodes. Loading boundary conditions are then applied to these elements and nodes. A network of these elements is known as Mesh.
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h. Finite element generation The maximum amount of time in a finite element analysis is spent on generating elements and nodal data. Preprocessor allows the user to generate nodes and elements automatically at the same time allowing control over size and number of elements. There are various types of elements that can be mapped or generated on various geometric entities. The elements developed by various automatic element generation capabilities of pre processor can be checked element characteristics that may need to be verified before the finite element analysis for connectivity, distortion-index etc. Generally, automatic mesh generating capabilities of pre processor are used rather than defining the nodes individually. If required nodes can be defined easily by defining the allocations or by translating the existing nodes. Also on one can plot, delete, or search nodes. i. Boundary conditions and loading After completion of the finite element model it has to constrain and load has to be applied to the model. User can define constraints and loads in various ways. All constraints and loads are assigned set ID. This helps the user to keep track of load cases. j. Model display During the construction and verification stages of the model it may be necessary to view it from different angles. It is useful to rotate the model with respect to the global system and view it from different angles. Pre processor offers these capabilities. By windowing feature pre processor allows the user to enlarge a specific area of the model for clarity and details. Pre processor also provides features like smoothness, scaling, regions, active set, etc for efficient model viewing and editing. k. Material defections All elements are defined by nodes, which have only their location defined. In the case of plate and shell elements there is no indication of thickness. This thickness can be given as element property. Property tables for a particular property set 1-D have to be input. Different types of elements have different properties for e.g. Beams Shell Springs Solids : Cross sectional area, moment of inertia etc : Thickness : Stiffness : None
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The user also needs to define material properties of the elements. For linear static analysis, modules of elasticity and Poissons ratio need to be provided. For heat transfer, coefficient of thermal expansion, densities etc. are required. They can be given to the elements by the material property set to 1-D. l. Solution The solution phase deals with the solution of the problem according to the problem definitions. All the tedious work of formulating and assembling of matrices are done by the computer and finally displacements are stress values are given as output. Some of the capabilities of the ANSYS are linear static analysis, non linear static analysis, transient dynamic analysis, etc. m. Post- processor It is a powerful user-friendly post-processing program using interactive color graphics. It has extensive plotting features for displaying the results obtained from the finite element analysis. One picture of the analysis results (i.e. the results in a visual form) can often reveal in seconds what would take an engineer hour to assess from a numerical output, say in tabular form. The engineer may also see the important aspects of the results that could be easily missed in a stack of numerical data. Employing state of art image enhancement techniques, facilities viewing of: Contours of stresses, displacements, temperatures, etc. Deform geometric plots Animated deformed shapes Time-history plots Solid sectioning Hidden line plot Light source shaded plot Boundary line plot etc.

The entire range of post processing options of different types of analysis can be
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accessed through the command/menu mode there by giving the user added flexibility and convenience.

3.3 THERMAL ANALYSIS

A thermal analysis calculates the temperature distribution and related thermal quantities in brake disk. Typical thermal quantities are: 1. The temperature distribution 2. The amount of heat lost or gained 3. Thermal fluxes 3.3.1 Types of thermal analysis 1. A steady state thermal analysis determines the temperature distribution and other thermal quantities under steady state loading conditions. A steady state loading condition is a situation where heat storage effects varying over a period of time can be ignored. 2. A transient thermal analysis determines the temperature distribution and other thermal quantities under conditions that varying over a period of time. 3.3.2 Planning the analysis In this step a compromise between the computer time and accuracy of the analysis is made. The various parameters set in analysis are given below: Thermal modeling Analysis type? Steady state or Transient? Thermal or Structural? Properties of the material? process of braking is done. Units SI Thermal h-method. Transient Thermal Isotropic

Objective of analysis- to find out the stress distribution in the brake disk when the

3.4 STRUCTURAL ANALYSIS

Structural analysis is the most common application of the finite element analysis. The term structural implies civil engineering structure such as bridge and building, but also naval, aeronautical and mechanical structure such as ship hulls, aircraft bodies and
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machine housing as well as mechanical components such as piston, machine parts and tools. 3.4.1 Types of structural analysis The seven types of structural analyses in ANSYS. One can perform the following types of structural analysis. Each of these analysis types are discussed as follows: Static analysis Modal analysis Harmonic analysis Transient dynamic analysis Spectrum analysis Buckling analysis Explicit dynamic analysis

3.4.2 Structural static analysis A static analysis calculates the effects of steady loading conditions on a structure, while ignoring inertia and damping effects such as those caused by time varying loads. A static analysis can, however include steady inertia loads (such as gravity and rotational velocity), and time varying loads that can be approximately as static equivalent loads (such as static equivalent wind and seismic loads).

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CHAPTER - 4 MODELING AND ANALYSIS

It is very difficult to exactly model the brake disk, in which there are still researches are going on to find out transient thermo elastic behavior of disk brake during braking applications. There is always a need of some assumptions to model any complex geometry. These assumptions are made, keeping in mind the difficulties involved in the theoretical calculation and the importance of the parameters that are taken and those which are ignored. In modeling we always ignore the things that are of less importance and have little impact on the analysis. The assumptions are made depending upon the details and accuracy required in modeling. The assumptions which are made while modeling the process are given below:1. The disk material is considered as homogeneous and isotropic. 2. The domain is considered as axis-symmetric. 3. Inertia and body force effects are negligible during the analysis. 4. The disk is stress free before the application of brake. 5. Brakes are applied on the front wheel. 6. The analysis is based on pure thermal loading and vibration and thus only stress level due to the above said is done. The analysis does not determine the life of the disk brake. 7. Only ambient air-cooling is taken into account and no forced Convection is taken. 8. The kinetic energy of the vehicle is lost through the brake disks i.e. no heat loss between the tyre and the road surface and deceleration is uniform. 9. The disk brake model used is of solid type and not ventilated one. 10. The thermal conductivity of the material used for the analysis is uniform throughout. 11. The specific heat of the material used is constant throughout and does not change with temperature.

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4.1

DEFINITION OF PROBLEM DOMAIN

Due to the application of brakes on the disk brake rotor, heat generation takes

place due to friction and this thermal flux has to be conducted and dispersed across the disk rotor cross section. The condition of braking is very much severe and thus the thermal analysis has to be carried out. The thermal loading as well as structure is axis-symmetric. Hence axis-symmetric analysis can be performed, but in this study we performed 3-D analysis, which is an exact representation for this thermal analysis. Thermal analysis is carried out and with the above load structural analysis performed for for analyzing the stability of the structure.

4.2

DIMENSIONS OF DISK BRAKE

The dimensions of brake disk used for transient thermal and static

structural analysis are shown in Figure. 4.1

Figure 4.1 Dimensions of Disc brakes

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The models of the disc brakes are developed using the other modeling softwares like Pro/E Wildfire 5.0.The imported models of the disc brakes are shown in the Figure 4.2.

Figure 4.2 Imported model of Disc brake

4.3

FINITE ELEMENT MESH

According to given specifications the element type chosen is solid 185.Solid 185 is

higher order version of the 3-D eight node thermal element. The element has 20 nodes with single degree of freedom, temperature, at each node. The 20-node elements have compatible temperature shape and are well suited to model curved boundaries. The 20-node thermal element is applicable to a 3-D, steady state or transient thermal analysis. If the model containing this element is also to be analyzed structurally, the element should be replaced by the equivalent structural element.
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Figure 4.3 Meshed model of the Disc brake

Figure 4.4 Loaded model of the disk brake

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4.4

SOLUTION
In the solution procedure, frontal solver is used. It involves After the applying the loads at the respective regions the deformations of the disc brake is obtained. The solved solutions are saved in the format of .db file. The report generated in the solution are taken as the images.

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CHAPTER - 5 RESULTS AND DISCUSSION 5.1 VALIDATION OF RESULTS

First of all, to validate the present method, a comparison of transient results with

the steady state solution of thermo elastic behaviors was performed for the operation condition of the constant hydraulic pressure P =3.006Mpa and angular velocity = 50 rad/s ( drag brake application) during 4.29 seconds. If the transient solution for this operation condition converges to the steady solution as time elapse, it can be regarded as validation of the applied transient scheme. The thermal boundary conditions used are adiabatic on the boundary of the inner and outer radius and the prescribed temperature condition T = 27C on the both boundaries along the radius of the lower and upper pad by assumption of the cooling state. The material properties and operation conditions used for the validation of the transient thermo elastic scheme are given in Table No -5.1 & 5.2. The time step t =0005 sec. was used.

5.2 MATERIALS ANALYZED

The various materials were analyzed in this work to get reasonable merits and demerits of them in the field of braking system. The materials properties are taken for the analysis purpose in this work. The various materials taken for work are, Cast iron Stainless steel Alumina E- Glass fiber 5.2.1 CAST IRON Cast iron is derived from pig iron, and while it usually refers to gray iron, it also identifies a large group of ferrous alloys which solidify with aeutectic. The color of a fractured surface can be used to identify an alloy. White cast iron is named after its white surface when fractured, due to its carbide impurities which allow cracks to pass straight through. Grey cast iron is named after its grey fractured surface, which occurs because the graphitic flakes deflect a passing crack and initiate countless new cracks as the material breaks.

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Table 5.1 Material properties of Cast iron Material Properties Thermal conductivity, K (w/m k) Density, Disk 57 7100 452 0.25 11 106

( kg/m3)

Specific heat , c (J/Kg k) Poissons ratio, v Thermal expansion , ( 106 / k ) Elastic modulus, E (GPa)

5.2.2 STAINLESS STEEL In metallurgy, stainless steel, also known as inox steel or inox from French "inoxydable", is defined as a steel alloy with a minimum of 10.5 or 11% chromium content by mass. Stainless steel does not corrode, rust or stain with water as ordinary steel does, but despite the name it is not fully stain-proof. It is also called corrosion-resistant steel or CRES when the alloy type and grade are not detailed, particularly in the aviation industry. There are different grades and surface finishes of stainless steel to suit the environment the alloy must endure. Stainless steel is used where both the properties of steel and resistance to corrosion are required. Table 5.2 Material properties of Stainless Steel Material Properties Thermal conductivity, K (w/m k) Density, Disk 17.2 7800 500 0.3 16 190

( kg/m3)

Specific heat , c(J/Kg k) Poissons ratio, v Thermal expansion , ( 106 / k ) Elastic modulus, E(GPa)

5.2.3 ALUMINA Aluminium oxide is an amphoteric oxide with the chemical formula Al2O3. It is commonly referred to as alumina (-alumina), or corundum in its crystalline form, as well as many other names, reflecting its widespread occurrence in nature and industry. Its most
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significant use is in the production of aluminium metal, although it is also used as an abrasive owing to its hardness and as a refractorymaterial owing to its high melting point. Table 5.3 Material properties of Alumina Material Properties Thermal conductivity, K (w/m k) Density, Disk 25 3720 880 0.3 8.6 300

( kg/m3)

Specific heat , c (J/Kg k) Poissons ratio, v Thermal expansion , ( 106 / k ) Elastic modulus, E (GPa)

5.2.4 E-GLASS FIBER E-Glass or electrical grade glass was originally developed for standoff insulators for electrical wiring. It was later found to have excellent fiber forming capabilities and is now used almost exclusively as the reinforcing phase in the material commonly known as fiber glass. Table 5.4 Material properties of E-Glass Fiber Material Properties Thermal conductivity, K (w/m k) Density, Disk 9 2600 810 0.22 5.4 82

( kg/m3)

Specific heat , c (J/Kg k) Poissons ratio, v Thermal expansion , ( 106 / k ) Elastic modulus, E (GPa)

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Figure 5.1 Von Mises Stress distribution in Cast Iron

Figure 5.2 Von Mises Stress distribution in Stainless Steel

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Figure 5.3 Von Mises Stress distribution in Alumina

Figure 5.4 Von Mises Stress distribution in E- Glass fiber

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Figure 5.5 Elastic Strain distribution in Cast Iron

Figure 5.6 Elastic Strain distribution in Stainless Steel

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Figure 5.7 Elastic Strain distribution in Alumina

Figure 5.8 Elastic Strain distribution in E- Glass fiber

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Figure 5.9 Average displacement in Cast Iron

Figure 5.10 Average displacement in Stainless Steel

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Figure 5.11 Average displacement in Alumina

Figure 5.12 Average displacement in E- Glass fiber

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CHAPTER 6 CONCLUSION
In this paper, the stress analysis of disk brakes in severe braking conditions has been performed. ANSYS software is applied to the stress problem with frictional heat generation. To obtain the behaviors appearing in the disc brake, the change in pressure and temperature were calculated to analyze the disc brake under severe conditions. Also, the fully implicit scheme is used to improve the accuracy of computations in the stress analysis. Through the axis symmetric disk brake model, the stress phenomenon on each of the friction surfaces between the contacting bodies has been investigated. The effects of the material properties on the contact ratio of friction surfaces are examined and the larger influential properties are found to be the thermal expansion coefficient and the elastic modulus. Based on these numerical results, the stress behaviors of the glass fiber composite disk brakes are also investigated along with metal matrix composites(Alumina). It is observed that the alumina based brakes can provide better brake performance than the isotropic ones because of uniform and mild pressure distributions. The present study can provide a useful design tool and improve the brake performance of disk brake system. From Table 6.1 we can say that all the values obtained from the analysis are less than their allowable values. Hence the brake disk design is safe based on the strength and rigidity criteria. It is concluded that the Alumina disc brake is better than the other compared materials for the present day applications. .

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Stress
8.00E+008 7.00E+008 6.00E+008

Stress value

5.00E+008 4.00E+008 3.00E+008 2.00E+008 1.00E+008 0.00E+000 CI SS AL E-GLASS

M aterials

Figure 6.1 Graph - Comparison of the stress

Strain value

0.00030 0.00025 0.00020 0.00015 0.00010 0.00005 0.00000 CI SS AL E-GLASS

Strain value

Materials

Figure 6.2 Graph - Comparison for Strain

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Displacement

0.08

0.06

Displacement

0.04

0.02

0.00 CI SS AL E-GLASS

Materials

Figure 6.3 Graph - Comparison for displacement

Table 6.1 Comparison of the result Von-mises stress Min 0.879e7 0.617e7 0.49e7 0.137e8 Max 0.822e9 0.480e9 0.27e9 0.65e9 Elastic strain Min 0.12e-3 0.102e-3 0.820e-4 0.137e-3 Max 0.3e-3 0.271e-3 0.2e-3 0.32e-3

Material Cast iron Stainless steel Alumina E-glass fiber

Deflection 0.07711 0.0698 0.0544 0.0594

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SCOPE FOR THE FURTHER STUDY

In the present investigation of thermal analysis of disk brake, a simplified disk brake without any vents, with only ambient air-cooling is analyzed by FEM package ANSYS. As future work, a complicated model of ventilated disk brake can be taken and there by forced convection to be considered in the analysis. The analysis still becomes complicated by considering variable thermal conductivity, variable specific heat and non uniform deceleration of vehicle. This can be considered for the future work.

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REFRENCES
1. KENNEDY, F. E., COLIN, F. FLOQUET, A. AND GLOVSKY, R. Improved Techniques for 2. Finite Element Analysis of Sliding Surface Temperatures. Westbury House page 138-150, (1984). LIN , J. -Y. AND CHEN, H. -T. Radial Axis symmetric Transient Heat Conduction in Composite Hollow Cylinders with Variable Thermal Conductivity, vol. 10, page 2- 33, (1992). 3. 4. BRILLA, J. Laplace Transform and New Mathematical Theory of Visco elasticity, vol. 32, page 187- 195, (1997). TSINOPOULOS, S. V, AGNANTIARIS, J. P. AND POLYZOS, D. An Advanced Boundary Element/Fast Fourier Transform Axis symmetric Formulation for Acoustic Radiation and Wave Scattering Problems, J.ACOUST. SOC. AMER., vol 105, page 1517-1526, (1999). 5. WANG, (1990). 6. 7. 8. 9. 10. FLOQUET, A. AND DUBOURG, M.-C. Non axis symmetric effects for three dimensional Analyses of a Brake, ASME J. Tribology, vol. 116, page 401-407, (1994). BURTON, R. A. Thermal Deformation in Frictionally Heated Contact, Wear, vol. 59, page 1- 20, (1980). ANDERSON, A. E. AND KNAPP, R. A. Hot Spotting in Automotive Friction System Wear, vol. 135, page 319-337, (1990). COMNINOU, M. AND DUNDURS, J. On the Barber Boundary Conditions for Thermo elastic Contact, ASME J, vol. 46, page 849-853, (1979). BARBER, J. R. Contact Problems Involving a Cooled Punch, J. Elasticity, vol. 8, page 409- 423, (1978). H. -C. AND BANERJEE, P. K.. Generalized Axis symmetric Elastodynamic Analysis by Boundary Element Method, vol. 30, page 115-131,

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