Final Year Project Presentation (2)
- 1. Thermal Analysis Investigation of Brake Discs Using Creo Final Year Project Presentation Saqib Ahmed (B00238797) Supervisor – David Kennedy
- 2. Overview of Project This project touches upon the following modules – Computer Aided Design (CAD) Thermal and Mechanical Design Race Engineering Analysis & Simulation Design Prototyping and Testing Motorsport Design Engineering Application Project
- 3. Overview of Problem for Vauxhall VX220 Brake Disc Assumptions can be made, where the thermal and mechanical loads will cause the brake disc to deform/fatigue/crack.
- 4. Sources Regarding Project Author Title Year Overview Method Y. Yildiz, M. Duzgun Stress analysis of ventilated brake discs using the finite element method 2010 Stress Analysis of ventilated disc brakes via FEM, crack formations Experimental & Computational (Analytical) V.M.M Thilak, R Krishnaraj, M Sakthivel, K Kanthavel, Deepan Marudachalam, R Palani Transient thermal and structural analysis of the rotor disc of disc brake 2011 Transient Thermal Analysis via ANSYS Computational & Analytical Haripal Singh, Harshdeep Shergill Thermal Analysis of Disc Brake Using Comsol 2012 Analysis of heat dissipation/heat generation during emergency braking, comparison of three materials (conduction, convection & radiation) Computational & Analytical Ameer Fareed Basha Shaik, Ch. Lakshmi Srinivas STRUCTURAL AND THERMAL ANALYSIS OF DISC BRAKE WITH AND WITHOUT CROSSDRILLED ROTAR OF RACE CAR 2012 Thermal Analysis using ANSYS Computational & Analytical K. Sowjanya, S. Suresh Structural analysis of disc brake rotor 2013 Creo Parametric model of brake, using ANSYS for Von Mises stress, deflection and normal stresses Computational & Analytical Metropolitan Police Brake Test – 50mph to 0mph 50 times (http://www.fleetnews.co.uk/news/2004/11/2/fleet-in-focus-the-met/18004/)
- 5. Main Research • Modelling of Problem • Experiment • Mechanical/Thermal Loading Validation • FEA of Brake Disc Designs
- 6. Modelling of Problem Original VX220 Modified
- 7. Experiment on Vehicle (Heat Rise) FL FR Non-Contact ∆T (oC) Initial Temp 20.6 20.2 IR (oC) Before After Run 1 20.2 23.5 3.3 Run 2 25.9 30.3 4.4 Run 3 23.9 32.4 8.5 Ek = 1/2mv2 Ek = Q = mC∆T Since mC = constant, ∆T directly proportional to Ek Q = mC∆T ∆T = 8.5 ≈ 129171.8 J
- 8. Validation (Mechanical Clamp Force) Front Force Calculations Pad Contact Area (mm) 46.2 mm Effective Disc Rad (mm) 120.9 mm 0.1209 m Clamp Force, F 12688 N Per Side of Brake Disc 6343.8 N • Corner weights Calculated • 65-35 Front-Rear Brake Balance • Disc Dia – 288 mm Area 1 = 11145.5mm Area 2 = 14537.0mm Area of Webbing = 3391.5mm
- 9. Validation (Mechanical Clamp Force) 10% Leigh-way for FEA Stress found on model – 3.7744MPa Hand Calculations 𝑆𝑡𝑟𝑒𝑠𝑠 = 𝐹𝑜𝑟𝑐𝑒 𝐴𝑟𝑒𝑎 = 12688 3391.5 = 3.7MPa 𝑆𝑡𝑟𝑎𝑖𝑛 = 𝑆𝑡𝑟𝑒𝑠𝑠 𝑌𝑜𝑢𝑛𝑔′ 𝑠 𝑀𝑜𝑑𝑢𝑙𝑢𝑠 𝑆𝑡𝑟𝑎𝑖𝑛 = ∆𝐿 𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝐿𝑒𝑛𝑔𝑡ℎ
- 10. Validation (Thermal Stress Analysis) Cast iron 4.5% C, ASTM A-48 Yield Strength = 130MPa Ultimate Tensile Strength = 200 MPa Original VX220 Modified
- 11. Validation (Thermal Stress Analysis) Original MaxStress = 2738 MPa Realistic = 1643MPa VX220 MaxStress = 1212.18 MPa Realistic = 727.317 MPa Modified MaxStress = 1305.11MPa Realistic = 783.072 MPa
- 12. FE Analysis of Brake Discs Mechanical plus Thermal Load Cases Consider the bolt holes added to the model since this will allow the model to be free to rotate around in the z-axis Angular Velocity and Acceleration calculation required Consider the scaling of results (very important!)
- 13. Problems and Limitations of Project Working out exact values for the analysis Centre of Gravity of vehicle Exact calibration of the heat gun Limitations with CAD/FEA Software no underlying shells or beams in the mechanical & thermal analysis Fine details aborting analysis on Creo Simulate
- 14. Discussion & Conclusion Discussion To be completed - Timeline of Project Assumptions from Thermal & Mechanical Analysis Conclusion • Modelling of Problem • Experiment • Mechanical/Thermal Loading Validation • FEA of Brake Disc Designs
- 15. Future Research Choice of materials (isotopes) Centre of Gravity of Vehicle Experiment (knife-edge) Implementing dimensional analysis Using a different FEA software which is more suitable (Comsol, ANYSYS, ABAQUS CAE) More demanding physical test (Metropolitan Police) Physical modelling of modified brake design in controlled conditions Manufacturing methods and heat treatment to components
- 16. Thank you for listening! Any Questions?
Editor's Notes
- #2: Hi my name is… 4th Year Project conducting it on the <title of project>
- #7: Talk about the three designs (revolve, pattern etc) Original shitty design, prone to cracking The one found on the vehicle now, with slight part coming out Final design – front disc is straight
- #8: Show pic of Vauxhall VX220 Talk about the speed (60.6 km/h) 3 runs taken Talk about apparatus (IR Non-Contact Heat Gun, Thermal Imager pic and talk about how the gun had to be calibrated) Talk about the relationship between the Ek, Q and delta T (equation) Results of this test – show table of the three runs Last one is the heat rise value that is taken; since heat is already generated in the components and heat flow shite blah blah blah
- #11: Show screenshots of the three different brake disc designs Mention the constraint added to the model (hub hole surface, fixed in x,y and z axis Comparison, and validate against the overview of the problem