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Volume 6, Issue 11, Nov 2015, pp. 114-122, Article ID: IJMET_06_11_014
Available online at
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=6&IType=11
ISSN Print: 0976-6340 and ISSN Online: 0976-6359
IAEME Publication
1. INTRODUCTION
1.1. BRAKE DISC
A disc brake is a type of brake that uses Calipers with brake pads. To resist the
motion. The brake disc (or rotor) is made of cast-iron, such as a vehicle axle, either to
reduce its rotational speed or to hold it stationary. The development and use of disctype brakes began in England in the 1890s. The first caliper-type automobile disc
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Firstly carry the old brake disc of Hyundai Santro Xing car from car garage. Analysis
each hole, stud, rotor, ventilation slots & his velocity & collect all data like as inner
diameter, outer diameter, hub length etc. & follow the brake disc to whole thesis
works.
And we have designed brake disc on designing software like as catia, solid works.
with properly correct diameter, length,
And import on ANSYS for analysis.
Find out good mashing, total deformation, and equivalent stress.
& Find out total deformation, equivalent stress, equivalent strain, Weight & some
other property of brake disc.
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Static analysis is a very important analysis for brake disc. By the help of static
analysis. We can find out the good total deformation, equivalent stress & other
property of static analysis.
A static analysis calculates the effects of steady loading conditions on a structure,
while ignoring inertia and damping effects, such as those caused by time-varying
loads. A static analysis can, however, include steady inertia loads (such as gravity and
rotational velocity), and time-varying loads that can be approximated as static
equivalent loads. Static analysis is probably the most common application of finite
element method the term structural (structure) implies not only civil engineering
structures such as bridges & buildings, but also naval, aeronautical and mechanical
structure such as ship hulls, aircraft bodies, & machine housing, such as piston
machine parts & tools. as well as mechanical component loads in static analysis
Static analysis is used to determine the displacements, stresses, strains, and forces in
structures or components caused by loads that do not induce significant inertia and
damping effects. Steady loading and response conditions are assumed; that is, the
loads and the structure's response are assumed to vary slowly with respect to
time. The kinds of loading that can be applied in a static analysis include.
A static analysis can be either linear or nonlinear. All types of nonlinearities are
allowed- large deformations, plasticity, creep, stress stiffening, contact (gap)
elements, hyperelastic elements, etc. This chapter focuses on linear static analyses,
with brief references to nonlinearities.
2. THERMAL ANALYSIS
Thermal analysis is important part of materials science where the properties of
materials are studied as they change with temperature with different condition.
Thermal analysis is a very important analysis for brake disc. By the help of thermal
analysis we can find out the temperature, heat flux & thermal analysis calculates the
other thermal quantities in a system or component. Like as
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3.2. TRANSIENTTHERMALANALYSIS
Transient thermal analysis determine temperature and other thermal quantities that
very over time engineers commonly use temperatures that a transient thermal analysis
calculate as input to structural analysis for thermal stress heat transfer applications. a
transient thermal analysis follows basically the same procedure as a steady-state
thermal analysis.
=
= 53c
TF = 53+ 32
TF = 85c
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T
T
=
= 43.26c
TF= 43.26 + 32
TF = 75c
=
= 56.84c
TF= 56.84+ 32
TF = 87c
=
= 48c
TF= 48+ 32
TF = 80C
By the help of final temperature we will find out heat flux of thermal analysis. on
ansys.
5. ANSYS
ANSYS is engineering analysis software (computer-aided engineering, or CAE). By
the help of this software we can analysis all value for comparing cast iron brake disc.
& other ansys software like as .in Simulation: Structural Mechanics, Metaphysics,
Fluid Dynamics, Explicit Dynamics, Electromagnetics, and Hydrodynamics
(AQWA). Workflow Technology: Ansys Workbench Platform, High-Performance
Computing, Geometry Interfaces, Simulation Process & Data Management. We
compare all four material alloy like as cast iron, structural steel, titanium, AL-NI-CO
alloy.
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Total deformation
Equivalent elastic strain
Stress
Factor of safety(f.o.s)
Heat flux
Weight
7. TOTAL DEFORMATION
Total deformation in static structural for structural steel alloy
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7.4. Factor of Safety & Weight of Structural Steel Alloy of Brake Disc
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8. FINAL RESULT
Table Details
Properties
Total (Mm) Deformation
Equivalent Stress (Mpa)
Equivalent Elastic Strain
Factor Of Safety
Temperature
(Tf) C
Heat Flux
(W/Mm)
Weight (Kg)
Cast Iron
(ALLOY)
0.0151
75.48
0.00047
3.71
Titanium
(ALLOY)
0.025
73.725
0.00078
12.613
AL-NI-CO
(ALLOY)
0.012
73.099
0.00031
9.5
Structural Steel
(ALLOY)
0.017
74.123
0.00037
3.3
85
75.26
87.5
80
0.4
0.188
0.161
0.570
3.00
1.5
2.84
3.2
9. DISCUSSION
We see that brake disc result is very good for new material alloy like as al-ni-co alloy
& titanium alloy .After compare from cast iron & structural steel. After Having
Modelled Some Error Is Generate in Brake Disc. But through the meshing we
decrease the errors & negative points. & apply both materials al-ni-co, titanium.
&structural steel. By this process of brake disc we create meshing for decreasing error
& negative points. Total deformation is good, stress, strain is good & main aim
reduced weight of brake disc. So we can say that al-ni-co alloy & titanium alloy is a
very good material alloy
10. CONCLUSION
1. By this methodology we can design brake disc on solid works. With standard data of
brake disc.
2. In this methodology of brake disc we create meshing for decreasing error & negative
points.
3. After modelling & meshing we calculate specific perimeter & variable data like as
force & moment of inertia static structural result. & heat flux & final temperature for
thermal analysis.
4. After Having Modelled Some Error Is Generate in Brake Disc.but through the
meshing we decrease the errors & negative points. & apply both materials al-ni-co,
titanium. & structural steel.
5. Broad conclusion of analysis carried out in this chapter is represented by table given
below. This table compares material al-ni-co and material titanium with material
CAST IRONin terms of maximum von misses Stress, maximum total deformation
and weight reduction.
6. Finally we calculate good material through total deformation, stress, strain, weight &
by some other property for brake disc.
7. al-ni-co alloy & titanium alloy is a good material for brake disc from compare to cast
iron & structural steel.
REFERENCE
[1]
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[4]
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