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Thermal analysis of disc brake

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Suresh Daravath

The document analyzes the thermal behavior of solid and ventilated disc brakes made from three materials - aluminum, grey cast iron, and structural steel - when subjected to braking forces through finite element analysis. Thermal simulations show that ventilated discs have better heat dissipation than solid discs, with maximum temperatures up to 8°F lower in ventilated models. Grey cast iron performed best overall with maximum temperatures under 150°F and was determined to meet strength and stability requirements for the application.

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THERMAL ANALYSIS OF DISC BRAKE
INTRODUCTION: • Friction based braking system is a common device to convert kinetic energy into thermal energy through a friction between the brake pads and the rotor faces. • Brake absorbs the kinetic energy of the rotating part and the energy is dissipated in the form of heat to the surroundings. • The main purpose of this study is to analysis the thermomechanical behavior of the dry contact of the brake disc during the braking phase. The coupled thermal analysis is used to determine the deformation and the disc for both solid and ventilated disc with three different materials to enhance performance of the rotor disc.
Governing equation Software packages 1. Solid works[modelling] 2. Ansys[thermal-analysis]
MODELING Ventilated disc brakes Solid disc brake
Flow chart :
MESHING Nodes-128713 Elements-84162 Nodes-1415428 Elements-826374
MATERIAL PROPERTIES Aluminum SteelGrey cast iron
ANALYZING [Solid body]
[ventilated body]
ALUMINUM GREY CAST IRON STRUCTURAL STEEL TOTAL HEAT FLUX DEFORMATION FOR A SOLID BODY
ALUMINUM GREY CAST IRON STRUCTURAL STEEL TOTAL HEAT FLUX DEFORMATION FOR A VENTILATED BODY
COMPARISON Material Max temp °f Min temp °f Grey cast iron 148.71 94.56 Aluminum 135.77 109.22 Steel 146.34 96.75 Material Max temp °f Min temp °f Grey cast iron 140.67 85.59 Aluminum 131.07 100.54 Steel 139.14 87.60 Ventilated modelSolid model
CONCLUSION • The main conclusions drawn from the program of work reported in this paper are as follows. • In this study, we presented results of the thermal behavior of full solid and ventilated discs in a steady state. we study the thermal behavior of a gray cast iron. In addition, the influence of disc ventilation on the thermal behavior of the discs brake was analyzed. The numerical simulation shows that radial ventilation plays a very significant role in cooling of the disc during the braking phase. • Thermal analysis is carried out for the application of braking force because of friction for the time duration of 1 seconds. • The maximum temperature obtained in grey cast iron rotor disc is at rubbing surface & is observed to be 148.71˚f. • The grey cast iron rotor disc is safe based on strength & stability criteria. • To achieve a best combination of parameters of rotor disc like size, type & materials, & thermal analysis for 3 different material combinations were done.
Thermal analysis of disc brake

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Thermal analysis of disc brake

  • 1. THERMAL ANALYSIS OF DISC BRAKE
  • 2. INTRODUCTION: • Friction based braking system is a common device to convert kinetic energy into thermal energy through a friction between the brake pads and the rotor faces. • Brake absorbs the kinetic energy of the rotating part and the energy is dissipated in the form of heat to the surroundings. • The main purpose of this study is to analysis the thermomechanical behavior of the dry contact of the brake disc during the braking phase. The coupled thermal analysis is used to determine the deformation and the disc for both solid and ventilated disc with three different materials to enhance performance of the rotor disc.
  • 3. Governing equation Software packages 1. Solid works[modelling] 2. Ansys[thermal-analysis]
  • 10. ALUMINUM GREY CAST IRON STRUCTURAL STEEL TOTAL HEAT FLUX DEFORMATION FOR A SOLID BODY
  • 11. ALUMINUM GREY CAST IRON STRUCTURAL STEEL TOTAL HEAT FLUX DEFORMATION FOR A VENTILATED BODY
  • 12. COMPARISON Material Max temp °f Min temp °f Grey cast iron 148.71 94.56 Aluminum 135.77 109.22 Steel 146.34 96.75 Material Max temp °f Min temp °f Grey cast iron 140.67 85.59 Aluminum 131.07 100.54 Steel 139.14 87.60 Ventilated modelSolid model
  • 13. CONCLUSION • The main conclusions drawn from the program of work reported in this paper are as follows. • In this study, we presented results of the thermal behavior of full solid and ventilated discs in a steady state. we study the thermal behavior of a gray cast iron. In addition, the influence of disc ventilation on the thermal behavior of the discs brake was analyzed. The numerical simulation shows that radial ventilation plays a very significant role in cooling of the disc during the braking phase. • Thermal analysis is carried out for the application of braking force because of friction for the time duration of 1 seconds. • The maximum temperature obtained in grey cast iron rotor disc is at rubbing surface & is observed to be 148.71˚f. • The grey cast iron rotor disc is safe based on strength & stability criteria. • To achieve a best combination of parameters of rotor disc like size, type & materials, & thermal analysis for 3 different material combinations were done.