Maximum Von Mises Research Articles

Structure analysis of a dragline tooth and its wear prediction

Dragline teeth are used to dig overburden rocks and fill the bucket by its action in surface mining. Thus, these teeth are very important for a better performance of the dragline. In the present investigation, efforts were made to determine the failure zone within the teeth through modeling, using the finite element software ANSYS workbench. The maximum deformation and maximum von-Mises stress were 0.286 mm and 801.38 MPa, respectively. From fatigue analysis, the minimum tool life was 24 540 cycle and the minimum factor of safety was 0.1 at the tip of the tool. Beyond the cutting edge (tip), the factor of safety was greater than 1.13. Finite element analysis was extended by varying the working load on the edge of the tool (68–86 tonnes) as well as the cutting angle (30°–36°). It was found that if the working load was increased, both corresponding maximum deformation and maximum von-Mises stress were increased, while the factor of safety was decreased. In the scanning electron microscopy analysis, wear phenomena such as rock intermixed, fracture of WC-grain, oxidized WC-grain, plastic deformation, cavity formation, cracking, and crushing were visible at magnification of 1000×.

Fatigue and thermal stress analysis of submerged steel pipes using ANSYS software

Submerged pipes are commonly used in the petroleum and oil manufacturing industries. These pipes include three-layered compound pipes, with inner, middle, and outer layers made of API 5L X70 steel, polypropylene, and concrete, respectively. Their different stresses, internal, external and thermal, were assessed individually. Thereafter, a combined analysis was carried out using the finite element method by means of ANSYS software. The results show that the deformations and stresses are in the safe zone, whereas thermal stresses can isolate the inner layer from the outside temperature. Moreover, fatigue resulting from environmental forces was studied to assess the maximum cycle lifetime number, deformation, stresses, and von Mises stress. Despite the most severe conditions chosen for the analysis, the pipeline was observed to withstand both negative environmental and operational conditions.

Finite element simulation of human trachea: Normal vs. surgically treated and scaffold implanted cases

Trachea experiences mechanical loads under physiological conditions. Surgery and tissue engineering change its mechanical conditions and may cause remodeling or damage. Here, we mechanically simulated one healthy trachea (from a 53-year-old brain-dead man) and as two examples, evaluated the impacts of surgery and scaffold implantation. Before patient's death, CT-scanning was performed at two respiratory pressures (0 and + 40 cm H2O for constructing 3D tracheal geometry at zero-stress state and model validation, respectively). After harvesting trachea, MRI, mechanical testing and hyperelastic modeling of tracheal tissues (cartilage, smooth muscle, and connective tissue) were performed. We simulated tracheal deformation and stress distribution under three conditions, including normal, 30%-resection of tracheal length and anastomosis (surgery) or its substitution with a cylindrical scaffold. In all models, the greatest stresses were produced in cartilaginous rings. Surgery-related extension reduced the physiologic cross-sectional deformability and increased stress levels in response to respiratory pressures, compared to normal trachea. For instance, maximum von-Mises stress in normal and operated trachea reached 355 kPa and 3.228 MPa, respectively. Scaffold was less deformable than normal trachea, though stress levels in both models were relatively close. This study provides an insight into the mechanics of human trachea and the impacts of surgery or scaffold implantation.

Experimental and Numerical Investigations on the Thermomechanical Behavior of 304 Stainless Steel/Q345R Composite Plate Weld Joint.

In this study, the welding process of 304 stainless steel/Q345R low alloy steel composite plate is modeled by experimental and finite element methods to study the complex thermomechanical behavior. The residual stress and microstructure evolution of composite plate in the welding process are also investigated. The welding thermal cycle curve and residual stress distribution at the joint are obtained by using thermocouple and blind-hole methods. Optical microscopy, scanning electron microscopy, and energy-dispersive X-ray spectroscopy were used to investigate the evolution of microstructure, morphology, and element diffusion of the joint. The results show that the maximum von Mises welding residual stress is 312 MPa, which is located in the bottom of the start point of the weld zone. The residual stress gradually decreases and tends to be stable along the direction from the weld to the base metal. In addition, a residual stress discontinuity is found at the interface between the bimetal. It is also found that the closer it is to the weld joint, the more uniform is the austenite distribution and the smaller are the grain sizes.

Design of a new magnesium-based anterior cruciate ligament interference screw using finite element analysis

Background/objectiveIn anterior cruciate ligament ​reconstruction, a tendon graft, anchored by interference screws (IFSs), is frequently used as a replacement for the damaged ligament. Generally, IFSs are classified as being either metallic or polymeric. Metallic screws have sharp threads that lacerate the graft, preventing solid fixation. These constructs are difficult to image ​and can limit bone--screw integration because of the higher stiffness of the screw. Polymeric materials are often a better match to bone's material properties, but lack the strength needed to hold grafts in place. Magnesium (Mg) is a material of great promise for orthopaedic applications. Mg has mechanical properties similar to bone, ability to be seen on magnetic resonance imagings, and promotes bone healing. However, questions still remain regarding the strength of Mg-based screws. Previous ex vivo ​animal experiments found stripping of the screw drive when the full torque was applied to Mg screws during surgery, preventing full insertion and poor graft fixation. The similar design of the Mg screw led to questions regarding the relationship between material properties and design, and the ultimate impact on mechanical behaviour. Thus, the objective of this study was to analyze the stresses in the screw head, a key factor in the stripping mechanism of IFS, then use that information to improve screw design, for this material. MethodsUsing finite element analysis, a comparison study of six drive designs (hexagonal, quadrangle, torx, trigonal, trilobe, and turbine) was performed. This was followed by a parametric analysis to determine appropriate drive depth and drive width. ResultsIt was observed that with a typical torque (2 ​Nm) used for screw insertion during anterior cruciate ligament reconstruction, the maximum von Mises and shear stress values were concentrated in the corners or turns of the drive, which could lead to stripping if the values were greater than the yield stress of Mg (193 ​MPa). With a four-time ​increase in drive depth to be fully driven and a 30% greater drive width, these maximum stress values were significantly decreased by more than 75%. ConclusionIt was concluded that improving the design of a Mg-based screw may increase surgical success rates, by decreasing device failure at insertion. The translational potential of this articleThe results of this work have the potential to improve designs of degradable IFSs, allowing for greater torque to be applied and thus greater screw fixation between host bone and the graft. Such a fixation will allow greater integration, better patient healing, and ultimately improved patient outcomes.

A three-dimensional finite element stress analysis of two different implant distributions supporting and retaining mandibular overdentures

Statement of Problem: Hinging mandibular overdentures retained by anterior interforaminal implants results in denture rotation and posterior basal bone resorption. Wide spread implant distribution and posterior implant placement can improve overdenture support. Aim of study: To evaluate the biomechanical aspects of novel implant distribution used to support mandibular overdentures and compare it with commonly used design. The novel design consists of mid-symphyseal and bilateral posterior implants in the first molar region as opposed to conventional design with anterior mid-symphyseal and bilateral implants in the canine region.Materials and Methods: Two finite element models were created. In the two models a mid-symphyseal implant was simulated. In the first model (D1), 2 more implants were placed in the canine region bilaterally while for the second model (D2), the 2 additional implants were placed posteriorly in the first molar region. Unilateral vertical and oblique loads were applied on central fossa of right first molar and palatal aspect of central incisors in each model. Von Mises stress distribution was evaluated in the implants and peri-implant bone. Denture displacement was also calculated for each model. Results: There was a slight increase in maximum Von-Mises stress values recorded in both implants and peri-implant bone under both vertical and oblique load in D2 when compared to D1. D1 showed higher denture displacement values when compared to D2. Conclusions: Posterior implant placement resulted in improved denture support and minimal denture displacement on the expense of transferring extra load to the posterior implants. However, increased functional load on posterior implants is expected to have a positive effect on preservation of the residual alveolar ridge. D2 is an acceptable alternative prosthodontic design to D1 when anatomical factor permits.

Design and Finite Element Analysis of a Foldable and Single-Arm Wheelchair Lift for M-Class Vehicles

Commercially, many types of lifts and ramps are available to help the wheelchair users getting on and off the vehicles. In this study, a foldable wheelchair lift, which has a single arm was analysed by Finite Element Method according to specified maximum carrying mass of 300 kg in Directive 2001/85/EC. Examination was carried out on the manufactured wheelchair lift to validate the result of Finite Element Analysis. Initial analyses have shown that the lift is insufficient to be safe. Hence a modification was performed on the lift. After the modification, maximum von-Mises stress was calculated as 300.15 MPa in the cantilever beam of the platform which is produced by S355JR quality steel. The largest deformation was measured as 82.4 mm and 78.3 mm on the manufactured lift and on the model, respectively. Modal analysis indicates the result of the first eight modes occurred in low frequencies.

The Complementary Functions Method Solution to the Functionally Graded Polar Orthotropic Rotating Hyperbolic Disks with Both Radially and Circumferentially Aligned Fibers

In the present study, efforts have been made to numerically evaluate elastic displacements and stresses in a convergent or divergent hyperbolic disk subjected to a centrifugal force of constant circular velocity. The disk material is assumed to be continuously radially functionally graded (FG) with two orthotropic materials based on the simplest Voigt rule with a power of volume fraction of two constituents. The fibers are assumed to be aligned along either radial (RR) or circumferential (CR) directions. Having been a second order differential equation with variable coefficients, the governing equation so-called Navier equation is first derived and then put in the form of two differential equations of first order. These two ordinary differential equation set is originally solved based on the initial value problem (IVP) by employing the Complementary Functions Method (CFM). The numerical results are verified with the corresponding benchmark results for uniform thickness FG polar orthotropic disks. The radial variation of the elastic fields in a hyperbolic disk is investigated for several boundary conditions, disk profile parameters, and the gradient parameter for both the radially and circumferentially aligned fibers. Some numerical results are also presented. Under the case that is considered in this study, it is revealed that the CR disk offers much higher elastic fields than RR disk under all boundary conditions. For a composite rotating disk rotating at a constant speed, it will be better to align fibers along the radial directions, to use convergent disk profiles, and to locate the material having higher radial stiffness at the outer surface. It is also disclosed that the location of the maximum Von-Mises equivalent stress in fixed-free disks varies regarding the fiber orientation.

Effect of whole-body vibration and sitting configurations on lumbar spinal loads of vehicle occupants

Whole-body vibration (WBV) has been identified as one of the serious risk factors leading to spinal disorders, particularly in professional drivers. Although the influential factors in this area have been investigated epidemiologically, finite element (FE) modeling can efficiently help us better understand the problem. In this study, a modified HYBRID III dummy FE model which was enhanced by detailed viscoelastic discs in the lumbar region was utilized to simulate the effect of WBV on lumbar spine loads. Spinal responses to the vertical sinusoidal vibrations of a generic seat were obtained and spinal injury risk factors were calculated. Effects of variation of excitation frequencies, three different seatback inclinations and four pre-defined occupant postures on the spinal loads were investigated as influential variables. Results showed that under sinusoidal loading with a frequency of 5 Hz and in a typical sitting configuration, disc forces remained in a safe range (<1700 N) for short term. Collagen Fibers strain (<0.3%) and intradiscal pressure (<1.15 MPa) also indicated that the spinal loads were in a safe range. Additionally, calculating the risk factor according to ISO 2631-5 (about R = 0.8) confirmed the low probability of an adverse health effect due to WBV in long term. Frequency-domain analysis showed the resonance frequency to be at f = 6.27 Hz. Although according to ISO/CD 2631-5 standard, the occupant experienced the highest risk of injury at f = 7 Hz, it was found that spinal compression load at f = 6 Hz was 7.7% higher than the compression load at f = 7 Hz. Seatback oriented at 75° exhibited the highest risk of injury, nevertheless, maximum von-Mises stress in disc annulus was observed at 70°. In the evaluation of occupant posture, lordotic and slouching postures were compared and the latter exhibited higher stress ranges resulting in higher injury risk factor. Results of the model demonstrated its aptness to predict the spinal disc injuries in response to various vibrational loading and boundary conditions.

Influence of residual stress on performance of AlN thin film based piezoelectric MEMS accelerometer structure

The presence of residual stress is inevitable and major constraint for MEMS devices as they induce deformation, fracture, fatigue and micro structural changes in the structure. This paper presents the influence of residual stresses (up to − 2100 MPa) on the performance of AlN based piezoelectric MEMS accelerometer structure. The MEMS structure consists of an AlN coated silicon proof mass (800 µm × 800 µm × 300 µm) suspended by four beams (400 µm × 200 µm × 10 µm). Under the influence of residual stress (− 2100 MPa), the first three modal frequencies (13.54 kHz, 20.95 kHz and 20.95 kHz) of the accelerometer structure are reduced to 5.19 kHz, 10.17 kHz and 10.17 kHz respectively. The location of proof mass deflection and maximum von-Mises stress also get altered. Hence the structure sensitivity is also modified from 3.64 × 10−2/g (at no residual stress) to 2.54 × 10−4/g (at − 2100 MPa). The damping factor of the structure also gets modified from 3.96 to 10.38 due to the residual stress. Thus, the accelerometer frequency response (3 dB bandwidth) is found to be diminished from 1.81 to 0.26 kHz due to the presence of residual stress.

Design of Remotely Controlled Hydraulic Bottle Jack for Automobile Applications

Remotely controlled hydraulic bottle jack was designed in this study to alleviate the difficulties encountered during auto servicing that requires certain choice of elevation. Major components of the hydraulic jack were housed in a metal casing of 220mmx220mmx180mm with 2mm thickness. Curb weight (weight of the car with all fluids and components but without the driver, passengers, and cargo) of several cars ranging from 1086kg-1970kg were determined using a scale at nearby automobile shop. Considering the weight of individual cars that the designed hydraulic jack elevated, the time required to attain upward stroke of the piston and specific height of elevation was recoded accordingly. The time varied between 1.2 minutes with specific height of 150 mm and 1.44 minutes with specific height of 112 mm. Half weight of 1970 kg (985 kg) was used as the load case in Finite Element Analysis (FEA) to check the stress deformations, displacement and equivalent strain. Maximum von-mises stress of 8.465x10 6 N/mm^2 was obtained which is below the yield strength of the jack piston material. Maximum displacement of 2.999x10 -1 mm and maximum equivalent strain of 3.56x10 -3 . Factor of safety was chosen on a scale of 1-10, and the colour chart in the analysis indicated blue colour in the range of 7-10 throughout the jack assembly. This was an indication that the jack is safe to operate under the aforementioned applied load. Therefore, adoption of remotely controlled hydraulic bottle jack can save time and energy required to elevate vehicles to working height.

Effect of thread depth and implant shape on stress distribution in anterior and posterior regions of mandible bone: A finite element analysis

The ability of modern implant dentistry to achieve goals such as normal contour, function, comfort, esthetics, and health to totally or partially edentulous patients guaranteed it to be more effective and reliable method for the rehabilitation process of many challenging clinical situations. In regard to this, the current study evaluates the effect of changing implant shape design parameters on interface stress distribution within the mandible bone. A numerical procedure based on finite element (FE) method was adopted to investigate the influence of using different body design and thread depth of the inserted implant on the final stress situation. For the purpose of evaluation, a three-dimensional realistic FE models of mandible bone and inserted implant were constructed and analyzed using a pack of engineering software (Solidworks, and ANSYS). Six different commercial implant models (cylindrical and tapered) with three different V-shaped thread depths (0.25 mm, 0.35 mm, and 0.45 mm) were designed to be used in this study. The suggested implants used in this study were threaded in two different locations of mandible bone; the anterior region (Type I model) and posterior region (Type II model). A vertical static load of 250 N was directly applied to the center of the suprastructure of the implant for each model. For both models, evaluations were achieved to figure out the stress distribution patterns and maximum equivalent von Mises. The results obtained after implementation of FE dental-implant models show that the highest stresses were located at the crestal cortical bone around the implant neck. In addition, the simulation study revealed that taper body implant had a higher peak value of von Mises stress than that of cylinder body implants in all types of bones. Moreover, a thread depth of 0.25 mm showed highest peak of maximum von Mises stresses for Type I and Type II models. The simulation results indicate that all models have the same von Mises stress distribution pattern and higher peak von Mises stresses of the cortical bone were seen in tapered implant body in contrast to the cylindrical body.

Load response of the natural tooth and dental implant: A comparative biomechanics study.

PURPOSEWhile dental implants have displayed high success rates, poor mechanical fixation is a common complication, and their biomechanical response to occlusal loading remains poorly understood. This study aimed to develop and validate a computational model of a natural first premolar and a dental implant with matching crown morphology, and quantify their mechanical response to loading at the occlusal surface.MATERIALS AND METHODSA finite-element model of the stomatognathic system comprising the mandible, first premolar and periodontal ligament (PDL) was developed based on a natural human tooth, and a model of a dental implant of identical occlusal geometry was also created. Occlusal loading was simulated using point forces applied at seven landmarks on each crown. Model predictions were validated using strain gauge measurements acquired during loading of matched physical models of the tooth and implant assemblies.RESULTSFor the natural tooth, the maximum vonMises stress (6.4 MPa) and maximal principal strains at the mandible (1.8 mε, −1.7 mε) were lower than those observed at the prosthetic tooth (12.5 MPa, 3.2 mε, and −4.4 mε, respectively). As occlusal load was applied more bucally relative to the tooth central axis, stress and strain magnitudes increased.CONCLUSIONOcclusal loading of the natural tooth results in lower stress-strain magnitudes in the underlying alveolar bone than those associated with a dental implant of matched occlusal anatomy. The PDL may function to mitigate axial and bending stress intensities resulting from off-centered occlusal loads. The findings may be useful in dental implant design, restoration material selection, and surgical planning.

Topology Optimization Of Industrial Manipulator-Link Considering Dynamic Loading

Abstract In the present work, mass of an industrial manipulator-link is minimized using topology optimization method. Topology optimization is established substantial method for mass reduction of structural and machine components. A single link of manipulator is considered for optimization. For optimizing the design region, minimum compliance is chosen as objective function. While robotic arm rotates continuously about a fixed end, applied force acts dynamically on the other end. In such case topology obtained at one angular position is not optimum for other angular positions. Hence, a single topology is not sufficient for dynamic loading condition. Here, a weighted density parameter approach is proposed to consider the dynamic effect and produce a single weighted-topology. To compare the performance of weighted-topology, performance values such as maximum Von-Mises stress and deflection are computed at all discrete angular positions. A MATLAB based routine is developed to generate the weighted-topology and to simulate the performance values. Further, the obtained results are validated using simulation software ANSYS Workbench 18.1. The optimal design of weighted-topology is proven as better compare to any other individual topologies at different angular positions.

Finite Element Analysis on Knee Joint with Leg Length Inequality

This study aims to investigate the effect of leg length discrepancy (LLD) on the joint reaction stress and strain of femur particularly in the knee joint. The knee joint model was developed using CATIA and imported into ANSYS to simulate the LLD case based on the value of the joint reaction force from the previous experimental study. The analysis was done under a linear static condition. The knee components were divided on three; bone (femur and tibia), cartilage (femoral cartilage and tibial plateau cartilage) and menisci. The effect of LLD on the knee joint was determined by observing the contour of equivalent stress and strain distribution on the knee joint components and the maximum equivalent von-Mises stress and strain. The result shows a higher value of stress and strain was found on the short leg compared to the long leg due to the LLD. The pattern of overall results shows that the magnitude of stress-strain is proportional to the level of increments in LLD. Since the short leg demonstrate the greater in stress and strain value, it is prone to experience failure in the future such as wear in cartilage.

Influence of Geometric Design Variable and Bone Quality on Stress Distribution for Zirconia Dental Implants-A 3D Finite Element Analysis

This study aims to investigate the effects of variable thread pitch on stress distribution in bones of different bone qualities under two different loading conditions (Vertical, and Horizontal) for a Zirconia dental implant. For this purpose, a three dimensional finite element model of the mandibular premolar section and three single threaded implants of 0.8 mm, 1.6 mm, 2.4 mm pitch was designed. Finite element analysis software was used to develop the model and three different bone qualities (Type II, Type III, and Type IV) were prepared. A vertical load of 200 N, and a horizontal load of 100 N was applied at the abutment surface. The von-Mises stress criterion was used to analyze the results. The crestal bony-region of the mandibular section was subjected to maximum von-Mises stresses for all bone qualities. The outcome of this study indicates that, horizontal loading had more influence on stress distribution than vertical loading, regardless of the bone qualities and pitch values. Varying the dental implant pitch does not cause any decrease in stress distribution in bone, when the bone density decreased. The study concluded that implants with minimum pitch values induced lesser stress values at the implant-bone interface.

FATIGUE FAILURE ANALYSIS OF BIKE CRANK ARM USING SOLIDWORKS SIMULATION

Fatigue analysis probes how cyclic random service loads can often lead to catastrophic structural failure of the component. In this research work the crank bar design of a Bike is validated for Fatigue analysis using SOLIDWORKS Simulation which enables designers to simulate Fatigue failure of the component using Stress Life (SN) method that is based upon standard material test to failure. Aluminum 6061 – T6 material is used in the design and Fatigue SN curve table data is taken from the SOLIDWORKS material library which is derived from material elastic modulus based on ASME Austenitic Steel curves. The crank arm length is 10 in and width is 1.5 in with overall constant thickness 0.8 in and crank mid-section thickness equals to 0.2 in. First the design is analyzed for Static strength by applying the bearing load of 350 lbs. The maximum VonMises stress calculated was 106.61 MPa which is below the allowable yield strength of the material 275 MPa. A fully reversible alternating stresses equivalent to static VonMises stress is loaded for 100,000 cycles which is the required life of the component. The total life calculated was 69,158 cycles which is less than 100,000 cycles and factor of safety is 0.93. The conclusion was the component has to be redesigned for Fatigue strength.

An Anisotropic Analysis of Human Femur Bone with Walking Posture: Experimental and Numerical Analysis

Load-bearing bones have a capacity to ground the load from the point of impact to the opposite end (distal end) of the same bone irrespective of the direction of (inclination) impact forces. This is only possible due to highly heterogeneous microstructure of bones. In such circumstances, it is unjustified to assume bone to be isotropic in nature. Therefore, a correction factor is introduced while assuming material property of the bone, and thus non-isotropic modeling was considered. In this study, stress analysis of proximal femur bone with isotropic and anisotropic (non-isotropic) material property is modeled while the reaction force corresponding to walking cycle is implemented at the femur head. The results showed a significant variation of 30–45% while evaluating Von-Mises stress and strain developed on the femur bone under different loading conditions. Maximum Von-Mises stress is found on the lateral-interior side of femur, while maximum strain is identified on the same plane near the neck region of femur head. This study concludes the significance of anisotropic modeling of femur bone subjected to variable loading condition.

3D FEA study on: Implant Threading Role on Selection of Implant and Crown Materials

AIM:This study deeply investigates the effect of dental implant threading and material selection on the mandibular bone under two different crown materials (Translucent Zirconia and Porcelain fused to metal).METHODS:Two different designs of single piece dental implants were supporting dummy crown above simplified bone geometry in two finite element models. Models components were created by general-purpose CAD/CAM engineering package and then assembled inside ANSYS before meshing and assigning materials. Compressive loading of 100 N and 45º oblique loading of 50 N were tested.RESULTS:Twenty-four case studies were analysed, and their results were compared. Micro thread reduces implant maximum Von Mises stress by about 50 to 70% than regular thread one. Oblique loading of 50 N will produce 4 to 5 times more maximum Von Mises values on implant body than 100 N vertical loading. Zero or negligible effect on the cortical bone was recorded when exchanging the tested crown material. Although titanium implant can also reduce cortical bone, Von Mises stress by 50 to 100% in comparison to reinforced PEKK (poly ether-ketone-ketone) or PEEK (poly-ether-ether-ketone).CONCLUSIONS:Reinforced PEKK and PEEK implants can represent a good alternative to titanium implants. Zirconia crown distributes the applied load better than Porcelain fused to a metal one. Regardless of the implant material, an implant with the micro thread has superior behaviour in comparison to a regular one. Zirconia crown above titanium implant with the micro thread may represent the best option for patient bone.

Design, Development and FE Thermal Analysis of a Radially Grooved Brake Disc Developed through Direct Metal Laser Sintering.

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.