Structural analysis is done on the disc brake to validate the strength of the disc brake and thermal analysis is done to analyze the thermal properties. The model uses the heat transfer interface in 3d and simulates the transient heat production, dissipation and transfer within the disc as it rotates slower and slower. Structural and thermal analysis of rotor disc of disc. The transient thermal analysis to determine the temperature distributions on the contact surface of a disc brake is performed. It is important to model the transient heating and the following convective cooling to determine the minimum interval between a series of similar brake engagements. Heat transfer modeling software for analyzing thermal effects. Dhale structural and thermal analysis of brake disc, ijedr 2014. The objective of this work is to investigate and analyze the temperature distribution of rotor disc during operation using comsol multiphysics. So, the model is meshed and then analysed to get the detail and correct result of the stress of the contact surface figure 5 thermal meshing of disc brake figure 6 structural meshing of disc brake. Comparative analysis of disc brake model for different.
Brake absorbs kinetic energy of the rotating parts wheels and the energy is dissipated in the form of heat energy to the surrounding atmosphere. The work uses the finite element analysis techniques to predict the temperature distribution on the brake disc and to identify the critical temperature. The work uses the finite element analysis techniques to predict the temperature distribution on the brake disc and to identify the critical temperature of the brake rotor disc. Maximum temperature of the disc during repeated braking applications. Neglecting drag and other losses outside the brakes, the brakes retardation power is given by the negative of the time derivative of the cars kinetic energy. Abstract transient thermal and structural analysis of the rotor disc of disk brake is aimed at evaluating the performance of disc brake rotor of a car under severe braking conditions and there by assist in disc rotor design and analysis. The model of brake disc as a 2d with dimensions is shown in figure. To analyze the effect of design on the cooling performance cfd software. In the past, surface roughness and wear at the pad interface have rarely been considered in studies of thermal analysis of a disc brake assembly using finite element method. The structural and thermal problems are coupled through frictional heat generation, thermal expansion, and thermal contact.
This is to understand the pressure force and friction force on the disc brake material,which can help to reduce the accident that may happen in each day. How to set up and run a simulation with comsol multiphysics a proper introduction on how to set up and run a model in comsol multiphysics is essential when learning how to use the software. We have performed thermal analysis using aluminum alloy, titanium alloy and gray cast iron on the disc brake and analysis made to know the distribution of the temperature in the steady state environment. To help the learning process, there is a streamlined. Thermal analysis on disc brakes rotor vipul h hingu, lecturer, mechanical department, sb polytechnic, kj campus savli abstract in this paper, authors present our results of thermal analysis of disc brake rotor used by twowheelers in india. Design and thermal analysis of disc brake for minimizing.
International journal on recent and innovation trends in computing and communication, 3, 149152. To perform the steady state thermal analysis of the disk brake rotor. In vbf system the frictional resistance applied to the brake disc can be varied by changing the effective disc radius. In this study, the thermal analysis of the disc brake during braking process has been presented. The experimental setup for the thermal analysis of brake disc consists of a bed on which an alternating current induction motor of 3 hp 3000rpm.
Citeseerx thermal analysis of disc brake using comsol. To analyze the effect of design on the cooling performance cfd software package, fluent is. Generally, brake system is designed to apply frictional resistance to stop the vehicle. Veryst engineering specializes in multiphysics problems involving solids, fluids, heat transfer, mass transfer, acoustics, and electromagnetics. Analysis of frictional heating and thermal expansion in a disc brake. Paper open access analysis of frictional heating and. Thermal analysis of solid and vented disc brake during the braking. Excerpt from the proceedings of the 20 comsol conference in bangalore modeling and analysis of thermal bimorph using comsol rachita shettar, dr b g sheeparamatti 2 basaveshwar engineering college bagalkot 587102 corresponding author. The standard disc brake two wheelers model using in ansys and done the thermal analysis and also calculate the heat flux, temperature of disc brake model.
Disc brake design is done through solidwork and analysis is. Here the disc brake is designed by using solidworks and analysis is done by ansys workbench r 14. A threedimensional finite element model with a moving heat source was developed with comsol multiphysics to predict the temperature. Thermal and structural analysis of disc brake for different. The thermal stress calculation was based on the selected specific time temperature field imported from the. In this section two thermally coupled disc brake analysis examples are discussed. The parameters for the disc and pad were selected from the existing literature. If the cooling is insufficient the disc overheats and results in brake failure. This paper attempts to consider these two aspects to predict temperature distributions in a reduced disc brake model. Analyze heat transfer by conduction, convection, and radiation with the heat transfer module, an addon product to the comsol multiphysics platform.
Thermal analysis of disc brake using comsol research trend. Disc brake model and analysis is done using ansys workbench 14. A comparative study was made between grey cast iron gci, asbestos, aluminium metal matrix. Transient thermal and structural analysis of the rotor disc of disk brake is aimed at evaluating the performance of disc brake rotor of a car under severe braking conditions and there by assist in disc rotor design and analysis. This paper attempts to consider these two aspects to predict temperature distributions in a. Heat is generated due frictional contact between pad and disc. Thermal analysis of a disc brake model considering a real. An investigation into usage of new materials is required which improve braking efficiency and provide. The braking process was simulated in laboratory and the experimental data was used to verify the simulation results. Finite element analysis technique is used to predict the frictional heat, temperature distribution and variation in disc thickness of the disc brake. Development of a thermal model using comsol multiphysics. Thermal analysis of brake disc 2015 linkedin slideshare.
Comparative study of the disk brake rotor by using cast. Transient thermal and structural analysis of the rotor. The friction heat, which is generated on the interface of the disc and pads, can cause high. Temperature field and thermal stress analyses of high. Feb 07, 2016 thermal analysis of brake disc 2015 1. Thermal analysis of two wheeler brake disc using ansys. To predict the temperature distribution on the disk brake rotor on the cylindrical surface of the disk brake rotor.
A computational finite element model of a brake disc for determining. Making use of the ac dc, structural mechanics, and heat transfer modules, we are able to fully describe and simulate the realtime effects of this electromechanical brake. Analysis of frictional heating and thermal expansion in a. The thermal mechanical properties for the axisymmetric model were taken from a paper by day and newcomb 1984 describing the analysis of an annular disc brake. Structural and thermal analysis of disc brake using solidworks and ansys 936 views. In this project, the cooling performance of two wheeler brake disc is analyzed by using two different disc designs. The heat transfer module includes a comprehensive set of features for investigating thermal designs and effects of heat loads.
The pad is made of a resinbonded composite friction material, and the disc is made of steel. The ability to accurately determine the thermal conductivity of samples is crucial in brake development, as it plays an important role in brake performance and longevity. Heat generation in a disc brake comsol multiphysics. Thermal analysis is carried out for the application of braking force because of friction. In vbf system the frictional resistance applied to the brake disc can be varied by changing the effective disc radius based on the pillion load. Jun 01, 20 step by step procedure of how to do steady state thermal analysis of a disc brake fsae in ansys workbench. The maximum temperature is reached after approximately 23 of the brake engagement time.
The disc brake used in the automobile is divided into two parts. Thermal deformation and stress analysis of disk brakes by finite element method. Thermal analysis of disc brake using comsol semantic scholar. Thermomechanical analysis of automotive disc brake. Hopefully this paper will help everyone to understand thermal analysis of disc brake rotor and how disc brake work more efficiently, which can help to reduce the accident that may happen in each day.
Abstract the disc brake is a mechanism that used for reducing speed or discontinuing the cycle of the vehicle. Citeseerx document details isaac councill, lee giles, pradeep teregowda. Catia software and thermal analysis is done in ansys software. Meshing of the brake disc and brake pads has been done using comsol multiphysics 5. Bhaskar design and analysis of disc brake, international journal of engineering trends and technology feb 2014. Thermal analysis of a solid brake disc sciencedirect. Thermal performance of disc brake and cfd analysis 2014012497 in this paper an effective technology of virtual thermal test of disc brake with several advanced analytic techniques was presented.
In this study, a typical disc brake system was modeled including brake disc and pads. Both fields are coupled to the wear evolution equation. For the single braking application, the simulation results for frictional heat generation shows hot spots being developed. A computational model for the heat generation and dissipation in a disk brake during braking and the following release period has been formulated. Thermomechanical analysis of automotive disc brake composite. A higher thermal conductivity means that the heat produced at the point of contact where the brake is engaged can be transmitted to the center of the brake more quickly, which results in better performance. Transient thermal and structural analysis of the rotor disc. Structural and thermal analysis of rotor disc of disc brake. Figure 3 models the temperature flow in a disk brake 1. A three dimensional model of disc brake has been created and simulated. We developed a 3d thermalstructural disc brake model involving representative brake discrotor and brake pads figure 1. The model meshed in comsol software for transient heat transfer analysis at first, then disc thermal stress was obtained from static structure analysis. Transient analysis of disk brake by using ansys software. Modeling of the complete disc brake is generated using comsol software.
This example models the transient heating, and final temperature, of a disc brake of a car in brakeandrelease sequence. Comparison can be done for deformation, stresses, temperature etc. The analysis has been conducted using comsol multiphysics software. The electromechanical response of a brake design comsol blog. Thermal analysis of solid and vented disc brake during the. The work uses the finite element analysis techniques to predict the temperature distribution on the brake disc and. For analysis ventilated disc brake was messed using triangular surface mesher. Thermal and mechanical model for the disc brake would be gen erated and solved using comsol multiphysics developed base on the finite element principle. Thermal analysis of rotor disc of disc brake of baja sae. Design and thermal analysis of disc brake using ansys.
Feb 16, 2016 braking system represents one of the most fundamental safety critical components in modern vehicles. Step by step procedure of how to do steady state thermal analysis of a disc brake fsae in ansys workbench. The previous figure visually shows that the vented disc is less heated than the solid disc. Modeling and analysis of thermal bimorph using comsol. With comsol multiphysics, it is not only possible to model the electromagnetic forces of the permanent magnet and electromagnetic coil, but also the coupled effects of the structural motion, contact pressure, frictional forces, and the thermal response of the brake over time. This work deals with the analysis of heat generation and dissipation in a disc brake of an car during panic braking and the following release period by using computer aided engineering software for three different materials of rotor disc. Pdf study on transient thermal analysis of a disc brake during. Macuzic et al thermal analysis of solid and vented disc brake during the braking process c d fig. Our modeling and analysis expertise includes fluidstructure interaction, thermalstructure interaction, structuralacoustic vibrations, conjugate heat transfer, joule heating, and microwave heating. The temperature distribution for vented disc at different time steps. Pdf structural and thermal analysis of rotor disc of disc brake. Paper open access analysis of frictional heating and thermal. The aim of this paper is to realize the purpose of the holes in the disk brake.
Modeling was done using catia v5r21 software and static and transient thermal analysis was done using ansys 15 software. It says that the aluminum alloy is subjected to more heat dissipation and. The complete mesh of the full disc consists of 77626 tetrahedral elements, while the complete mesh of the vented disc consists of 95341 tetrahedral elements. Conclusion the main conclusions drawn from the program of work reported in this paper are as follows. The steady state thermal analysis of two wheeler disc rotor aimed towards the evaluating the braking performance of two wheeler disc brake under braking condition. Finite element analysis fea techniques are used to envisage the temperature distribution and to spot the critical temperature on the disc for materials using analysis diverse software comsol multiphysics. Numerical analysis of thermoelastic contact problem of. Conduction to describe conduction that occurs in any material, you can define the thermal conductivity as isotropic or anisotropic, and it may be constant or. The issue of nonuniform frictional heating effects of mutual slipping of a disc over fixed pads is tested using fe models with the several possible to occur in automotive application heat transfer coefficients. In his keynote talk at the comsol conference 2018 lausanne, andri bezzola of. With the virtual thermal test process, thermal performance of brake system could be easily evaluated without any possibility of great errors that. This is significant to understand the action force and friction force on the disc brake new material, how disc brake works more efficiently which can help to decrease the accidents. In this paper mathematical inputs, and thermal loads of brake rotor, calculations of different parameters required for thermal analysis is done by taking suitable assumptions. However, we need sources of heat simulations to map the tab to establish its thermal mapping.
The model simulates the braking action by investigating the thermal behaviour occurring on the disc and pad surfaces during this period. This paper deals with the transient thermal analysis of brake disc of variable braking force vbf system using computer software ansys. Thermomechanical analysis of automotive disc brake composite rotor. The objective of this work is to investigate and analyze the temperature distribution of rotor disc during operation using comsol. This work illustrates the modeling of frictional heating in a disc brake of a car using comsol multiphysics software. Haripal singh and harshdeep shergill 2012 thermal analysis of disc brake using comsol, international journal on emerging technologies 31. The disc is allowed to reach the desired speed and the brake is applied by the help of brake lever. Catia is a 3d modeling software widely used in the design.