Abstract
The present research work analyzed the effect of design modification with radial grooves on disc brake performance and its thermal behavior by using additive manufacturing based 3D printed material maraging steel. Temperature distribution across the disc surface was estimated with different boundary conditions such as rotor speed, braking pressure, and braking time. Design modification and number of radial grooves were decided based on existing dimensions. Radial grooves were incorporated on disc surface through Direct Metal Laser Sintering (DMLS) process to increase surface area for maximum heat dissipation and reduce the stresses induced during braking process. The radial grooves act as a cooling channels which provides an effective means of cooling the disc surface which is under severe condition of sudden fall and rise of temperatures during running conditions. ANSYS software is used for transient structural and thermal analysis to investigate the variations in temperatures profile across the disc with induced heat flux. FE based thermo-structural analysis was done to determine thermal strains induced in disc due to sudden temperature fluctuations. The maximum temperature and Von Mises stress in disc brake without grooves on disc surface were observed which can severely affect thermal fatigue and rupture brake disc surface. It was been observed by incorporating the radial grooves that the disc brake surface is thermally stable. Experimental results are in good agreement with FE thermal analysis. DMLS provides easy fabrication of disc brake with radial grooves and enhancement of disc brake performance at higher speeds and temperatures. Therefore, DMLS provides an effective means of implementing product development technology.
Highlights
One of the remarkable additive manufacturing (AM) processes that allows direct production by means of material layer addition is direct metal laser sintering, which was developed to overcome the disadvantages of traditional processes
An attempt was made to study the effect of design modification on disc brake surface incorporated with radial grooves
finite element (FE) Thermal Analysis was performed for analyzing thermal aspects with geometrical parameters influencing structural and thermal analysis of disc brakes without and with radial grooves
Summary
One of the remarkable additive manufacturing (AM) processes that allows direct production by means of material layer addition is direct metal laser sintering, which was developed to overcome the disadvantages of traditional processes. Different types of metals can be processed through DMLS; most common metals used for this process are aluminum alloys, nickel alloys, tool steels and stainless steels In this present work, maraging steel was considered to study thermal behavior of 3D printed metal under sudden increase and decrease of temperature conditions. Maraging steel is most suitable for DMLS, since they have good weldability property at micro level due to micron-sized melt-pool in the DMLS process with high cooling rates The property of these steels is proven to be well-matched with typical heavy duty applications in aerospace, automobile and tooling industries. This research work designed a disc brake with modifications on disc surface with radial grooves and these modifications were achieved using DMLS processes for easy fabrication.
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