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THERMAL AND STRUCTURAL ANALYSIS

OF BRAKE DISC
(TWO WHEELER)

PROJECT MEMBERS
J.Paul Gnanam (950713114091)
R.Sahaya Nirmal Beno (950713114111)
S.Roshan Antony Abishek(950713114108)
M.Muthupandi (950713114079)
Under the guidance of Mr.U.Nainar M.E(AP)
DEPARTMENT OF MECHANICAL ENGINEERING,FXEC
INTRODUCTION
Braking is a process which converts the kinetic energy of the vehicle
into mechanical energy which must be dissipated in the form of heat.
The disc brake is a device for deaccelerating or stopping the rotation
of a wheel. A brake disc (or rotor) usually made of cast iron or stainless
steel, is connected to the wheel and/or the axle. Friction material in
the form of brake pads (mounted on a device called a brake calliper) is
forced mechanically, hydraulically, pneumatically or
electromagnetically against both sides of the disc to stop the
wheel.Finite element (FE) models of the brake-disc are created using
SOLIDWORKS and simulated using ANSYS which is based on the finite
element method (FEM). In this project,Coupled Analysis (Structural &
Thermal analysis) is performed in order to find the strength of the disc
brake.In structural analysis total deformation, equivalent stress for the
design is found and in thermal analysis temperature distribution and
heat fluxes to be calculated by varying the different materials of the
PROBLEM STATEMENT
During braking, the kinetic energy of a moving vehicle get
converted into thermal energy through friction between
the brake disc and pad. The heat generated between the
brake pad & disc has to be dissipated into the surrounding
atmosphere.This heat transfer takes place by conduction,
convection and somewhat by radiation.Braking
performance of vehicle can be significantly affected by the
temperature. Poor heat dissipation may cause brake
fade,pneumatic wear,brake fluid vapourization,bearing
failure,noise,thermal cracks and hotspots.Then it is
important to analyze the thermal performance of the disc
brake system to predict the increase in temperature
during braking.
OBJECTIVES
The main objective is to predict

The temperature distribution throughout the brake disc.

The coupled field analysis i.e.thermal to static structural


analysis which gives thermal stresses and their corresponding
displacement in the brake disc due to the application of
temperature.

Best material for the brake disc based on the comparision of


above results.
METHODOLOGY
2.Steady
SOLIDWOR 1.Import state
KS the iges file thermal
analysis

3.Static
1.Create
ANSYS structural
the model
analysis

3.Save the
2.Build the
file into RESULTS
model
iges format
MODELLING
In this project,BAJAJ PULSAR 150cc model is taken for analysis.Modelling is
done on solidworks 2015 software.

Specification

Outer Diameter of the brake disc = 240mm


Inner Diameter of the brake disc = 110mm
Diameter of hole on the brake pad area = 7mm
No of holes in the brake plad area = 36
Diameter of hole in the wheel hub assembly = 5mm
No of holes in the wheel hub assembly = 6
Inner radius of the brake pad from the center = 89mm
Outer radius of the brake pad from the centre = 115mm
Kerb weight of the vehicle = 144kg
Thickness of the brake disc = 4mm
Brake disc material = Gray cast iron.
Brake Pad
Specification

Inner radius (Ri) = 89mm

Outer radius (Ro) = 115mm


CALCULATION

Speed of the vehicle, u = 54kmph

= 54*(5/18)

u = 15 m/s.

Velocity, v = u + at (final velocity = 0)

0 = 15 + a(4)

a = -3.75 m/s

Distance, x = ut + at

= {(15*4) + (()(-3.75)(4))}

x = 30 m.
Kinetic energy, K.E = mv

= *200*15 {m=mass of the vehicle and the driver=200


kg}

K.E = 22500 J

Rubbing Area A =2r

= 2*3.14*(0.115 - 0.089)

= 0.0333 m.

Drag Force Fd = ***Cd*A

= *15*1.2*0.5*(0.45*1.866)

Fd = 56.6797N
Friction Force Fn = w

= 0.65*9.81*100

Fn = 637.65 N

Total Heat Generated = K.E - (Fd*x) (Fn*x)

= 22500 (56.679*30) (637.65*30)

= 1670.13 J

The analysis is carried by taking the brake efficiency as 15% for the calculation of heat flux.(total heat
generated = 1670.13*0.15 = 250.5195 J)

Heat Flux, = heat generated/(time*rubbing area)

= 250.5195/(4*0.0333)

= 1880.77 w/m