Optimization of Brake Disc Thickness and Radius Using Different Disc Brake Materials by FEM

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Addis Ababa University


The main purpose of this study is the optimization of disc brake materials by changing the radius and the thickness of the disc using different materials to choose the optimum disc brake material. The modelling of disc brake is made in CATIA software, the thermal and structure analysis is done using ANSYS workbench. In this research, a transient thermal and structural analysis was carried out to investigate the temperature variation across the disc and the total heat flux using ANSYS software. The thermal-structural analysis is then used to determine the deformation established and stresses in the disc. In all cases when the dimensions of disc model increase temperature, deformation and equivalent stress decrease. For example the deformation of cast iron decreases 7.0616e-5m to 5.4009e-5m when we change the model. For the side of the material by varying the properties of the materials, the better material for this study is the aluminium alloys 7075 with silicon carbide SiC/AL7075 because it has the minimum deformation 3.6367e-5 for model3. Finally this thesis suggests the SiC/AL7075 to be used disc brake material for the future with the model3.



Disc brake, cast iron, composite materials, dimension, ANSYS software, CATIA software