Steady State Thermal and Structural Analysis of Disc Brake Using Solidworks And Ansys (Case Study on Disc Brake of Volvo B11r Model Bus)

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Date

2020-08

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Addis Ababa University

Abstract

Braking system represents one of the most fundamental and critical safety components in modern vehicles. Brake absorbs kinetic energy of the rotating parts (Wheels) and the energy dissipated in the form of heat energy to the surrounding atmosphere. It decelerates or stops the vehicle. The thesis describes the finite element analysis techniques to predict the failure region on the pre maturity faller on disc brake to identify the critical locations of the components. The disc brake implemented on the front axle model with gray cast iron materials were studied in Disc brake which commonly used in auto motives. Despite all the stresses experience by the disc doesn’t damage the disc due to high tensile strength but the disc may fail under fatigue loading. There is frictional heat generated over disc surfaces, which leads to high temperature. Due to number of brake actuation, stress and deformations have generated on the disc surface. Hence, it reduce the overall performance and efficiency of the brake system. The problem in Volvo B11R Bus of ODAA integrated plc, which is imported in May, 2019 is that their disc brake is involving premature failure. i.e before service life of 500,000 km. This will initiate accident and leads to loss to the supplier due to complain from the customer. The objective of this paper was to model and steady state thermal and static structural analysis using finite element method (FEM). The method used to this research is to obtain necessarily data to study parametric values are retention time, force and torque. In order to make compare between actual prematurity failure and ANSYS result values decreasing torque and force while keeping retention time and mesh size at constant result in decreasing in both total deformation and Von miss stress. The maximum total deformation is 2.2424e-005m, the Von miss stress is 1.067e+008 Pa compressive ultimate strength 8.2e+008 pa, tensile ultimate strength 2.4e+008, compressive yield strength 1.e+009, tensile yield strength 1.e+008 and temperature result 420 ℃ . The ANSYS result shows that the crack that is happening in the bus’s disc break is due to the increase in toque, force and temperature which result in higher deformation and stress. Thus we obtained the values of total deformation, Von-miss stress and thermal effects on disc brake, and interpreted them to explain the cause of the failure.

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Keywords

Disc Brake, Solid work, ANSYS, FEA (finite element analysis)

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