Abstract
Brakes are the most important component of any automobile. Brakes provide the ability to reduce or bring automobile to a complete stop. The process of braking is usually achieved by applying pressure to the brake discs. The main objective of this research paper is to propose an appropriate design and to perform analysis of a suitable brake rotor to enhance the performance of the high-speed car. The design of the brake disc is modelled using Solid works and the analysis is carried out using Ansys software. The analysis has been conducted by considering stainless steel and grey cast iron using same brake rotor design so that optimal choice of brake disc can be considered. The analysis considered involves static structural analysis and steady state thermal analysis considering specific parameters on brake rotor to increase the life of brake rotor. From the analysis it is found that the performance and life of disc brake depends upon heat dissipation. From the analysis results it can be concluded that grey cast iron has performed better as compared to stainless steel as this material has anti-fade properties which improves the life of the brake rotor.
Highlights
Disc brakes are commonly used in automobile applications [1] and it uses calipers to apply pressure against a disc or rotor to create friction [2,3,4]
In case of static structural analysis, the maximum strain, stress, shear stress and total deformation has been studied whereas in case of steady state thermal analysis, total temperature and heat flux analysis have been studied. From this the following conclusions can be drawn. – From static structural analysis it is observed that, the maximum strain and total deformation is less in case of stainless steel as compared to grey cast iron whereas maximum stress is less in case of grey cast iron in comparison with stainless steel
The shear stress is less in case of grey cast iron as compared to stainless steel. – From static structural analysis it is observed that equivalent strain and total deformation in case of grey cast iron is 9.96% and 12.6% higher than martensitic stainless steel whereas equivalent stress and shear stress in case of grey cast iron is 38% and 38.1% lower than martensitic stainless steel. – From steady state thermal analysis, it can be concluded that the temperature distribution remains same in case of both stainless steel and grey cast iron whereas the heat distribution (Total heat flux) is more in case of grey cast iron as compared to stainless steel
Summary
Disc brakes are commonly used in automobile applications [1] and it uses calipers to apply pressure against a disc or rotor to create friction [2,3,4]. Subhasis et al [6] have studied temperature distribution using FEA in case of disc brake Their main objective was to study distribution of temperature of rotor disc and to identify critical temperature considering convection and radiation parameters for Asbestos, AMMC (Aluminum metal matrix composites) and GCI (Grey cast iron) materials. They concluded that heat generation is less in case of AMMC material as compared to GCI. Dakhil et al [9] have studied performance of disc brake system by considering cast iron and stainless-steel material They studied the temperature distribution, stresses, and deformation in case of disc brake using finite
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