Thermal Stress Analysis of Disc Brake Rotor By Finite Element Method

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Disc brakes are exposed to large temperature resulting large thermal stress during routine braking. These large temperature extrusions have two possible outcomes: fade that generates reduction in stopping power; and large amount of plastic deformation that generates low fatigue life in the brake rotor. The aim of the present work is to investigate the temperature and thermal stress response of gray cast iron disc brake during first braking phase using analytical, as well as finite element (FE) method and comparing the result. The area of study is concentrated on temperature variation as a function of thickness only. Only the areas exposed to high temperature is selected for analysis, specifically the rotor, by excluding hub and vanes because they are for from disc-pad contact. One particular existing brake disc design for a SUV car of model DD6470C is chosen for the investigation. The dimensions, material property and maximum allowable speed of this car are used as an input both for analytical and finite element method. Analytically the distribution of temperature caused by applied heat flux as a function of disc thickness is solved by the method of partial solutions. The finite element simulation for the coupled transient thermal field and stress field is carried out by separate data base thermalstructural coupled method based on ANSYS 14.0 to evaluate the stress fields and temperature. Due to circumferential and axial symmetry of the disc, only half thickness of the disc is used axially, and 15.65° is used circumferentially in finite element analysis by ANSYS. The results show maximum temperature and compressive stress components at the surface and these affects tribological properties such as damage and failure at the surface of the disc. In addition, it was found that high thermal load leads to brake fade and low fatigue life time of cast iron due to surface rupture of the rotor. Good agreement was obtained between FEM and analytical analysis braking cycles to failure. Key words: Analytical analysis, Heat flux, Finite element method, Stress components,



Analytical analysis; Heat flux; Finite element method; Stress components