ANSYS-BASED STRUCTURAL AND THERMAL ANALYSIS OF A DISC BRAKE

Abstract

Abstract The braking system is one of the most important safety components in modern vehicles. Brake absorbs the kinetic energy of the moving parts (wheels) ann t:lissipatco it in u,., form Ot thermal energy into the surrounding atmosphere. It slows or stops the vehicle. When braking is given to a disc brake, it is · subjected to considerable stress, which can cause structural and wear difficulties. As a result, for optimal performance, structural, stress, and thermal evaluations are favored when selecting low-stress materials. The purpose of this research is to simulate and investigate stress concentration, structural deformation, and thermal gradient of disc brakes. The disc brake is created using Solidworks and analyzed using ANSYS workbench R 14.5.

Specification

DESCRIPTION
~ Structural Analysis:
• Assessing stress distribution, deformation, and potential failure points under various braking
forces.
• Optimizing the geometry and material composition of the disc to enhance strength and reduce
weight without compromising safety.
~ Thermal Analysis:
• Simulating heat generation due to friction during braking.
• Evaluating temperature distribution and heat dissipation efficiency across the disc surface.
• Identifying areas prone to thermal deformation or fatigue and proposing design improvements.
~ Integration of Results:
• Combining structural and thermal results to determine the coupled effects of thermal and
mechanical stresses.
• Validating the model through experimental data or existing benchmarks to ensure accuracy and
reliabilitY.
BACKGROUND ART
The disc brake is an essential component of the vehicle's retardation system. It is a type of brake that
employs calipers to squeeze pairs of pads against a disc to generate friction. Friction slows the rotation of
a shaft (vehicle axle) to keep it stationary or reduce the rotational speed. Disc brakes are often made of
cast iron or ceramic composites like carbon, aluminum, and silica. The friction substance known as a
brake pad is designed to engage with both sides of the disc mechanically or pneumatically. This friction
substance causes the disk to slow down or halt.
Temperature rises as a result of frictional heat generated at the disc and pad interface. When this
temperature surpasses the critical value for the particular material, it causes catastrophic occurrences
such as brake failure, rapid wear and failure of bearings, heat cracking, and braking fluid vaporization.
Furthermore, heat generated at the disc pad interface causes global deformation in both the disc and the
pad. Common deformations include coning and buckling.
NOVEL SYSTEM AND METHOD
~ A structured framework that automates the preprocessing, simulation, and postprocessing stages
within ANSYS.
~ Simulation of braking forces to determine stress distribution, deformation, and critical failure
zones.
~ Accurate modeling of frictional heat generation during braking events.
~ A combined structural and thermal analysis approach to evaluate the interplay of mechanical
stresses and thermal effects.



CLAIMS:
1. Providing a disc brake model with specified geometric, material, and boundary conditions;
2. Conducting a structural analysis to evaluate stress dislribution, deformation, and potential failure
zones under braking forces;
3. Performing a thermal analysis to simulate heal generation due to friction, temperature distribution,
and heat dissipation characteristics; and
4. Integrating the results of the structural and thermal analyses to identify coupled effects of
mechanical slresses and thermal loads on the disc brake system.
5. A computational piattorm configured to execute finite element analysis using ANSYS software.

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