Structural and Thermal Analysis on Rotor of Disc Brake by Varying Materials Using ANSYS

Abstract

A brake disk rotor forms pan of a foundation brake and rotates with the wheel hub assembly. The disc brake works on the principle of pascal’s law which states that whenever pressure is applied to a fluid as it should be confined then it is equally distributed throughout the fluid in all directions and the force acting right angle to walls of the surface contact with the fluid. A brake disk rotor forms pan of a foundation brake and rotates with the wheel hub assembly. The main function of a foundation brake is to generate a retarding torque by converting mechanical energy to thermal energy by virtue of the frictional work done in relative sliding at the rotor-pad interface.
The main objective of the study is to design a disc brake rotor. Here two models of the disc brake rotor are considered without holes and with holes. And then structural and thermal analysis are done on the disc brake rotor made of two models with holes and without holes by varying the materials
In this thesis, comparison is done by varying materials with conventional materials and functionally graded materials, conventional materials are Cast Iron, Aluminum Alloy 6061. The Functionally Graded Material with metal Aluminum alloy 6061 using Ceramic as interface zone is taken for analysis. FGM’s are considered for volume fractions of K=2. Theoretical calculations are done to calculate the material properties for each layer up to 10 layers.
3D modeling of the disc brake rotor is done in Pro/Engineer wildfire 5.0 and analysis is done in ANSYS 14.5