Thermal Analysis of Disc Brake System

Brakes are one of the most significant safety systems in an automobile. In the braking process, the rotor will be exposed to large stresses which result in surface cracking, overheating of brake fluid, seals and other components. Therefore one of the main tasks of the braking system is to reduce the surface temperature of the brake rotor. This can be achieved by choosing the right material which will undergo the least thermal stresses. In this project, thermal analysis for vented disc brake rotor of Mahindra Bolero’s done, for providing an efficient material for disc brake rotor and brake pads which can dissipate heat generated during braking at faster rate and also being structurally safe. Keywords: Braking system, Disc Brake Rotor, Thermal, Structural Analysis, CATIA V5, ANSYS WORKBENCH

Transient Thermal Analysis of Disk Brake System under Varying Velocities and Pad Material Properties

The Enormous progressions in the field of automobiles have led their car engines to have enriched brake power in vehicles. The braking system’s efficiency should be at par with the engine to decelerate the car from a given speed within a less braking distance. The disc rotor and brake pads design and material while counting other impacting factors contribute to braking efficiency. The disc rotor will be exposed to large stresses which result in surface cracking, overheating of brake fluid, seals and other components. Many factors are affecting it as coefficient of friction between brake pad and disk rotor surface, thermal conductivity of pad material. Hence to reduce thermal stresses we can choose right pad material. In this project, thermal analysis for vented disc brake rotor of Mahindra Bolero’s done, for providing an efficient material for disc brake rotor and brake pads with 0 to 12 % of steel powder as filler materials are used which can dissipate heat generated during braking at faster rate and also being structurally safe Keywords: Braking system, Disc Brake Rotor, Thermal, Structural Analysis, CATIA V5, ANSYS WORKBENCH, Pad Material properties

Transient thermal analyses of an integrated brake rotor and wheel hub for heavy duty vehicles

In this study, transient thermal analyses for a new integrated rotor and wheel hub concept are performed by consideration of convection, conduction and radiation effects. Test methods used for the characterization and certification purposes are constructed in a simulation environment and the effect of different ventilation vanes and rotor-hub arrangements on heat transfer mechanism is examined and the details are summarized for a reliable simulation process. Validated procedures are used to report a series of characterization and certification analyses, namely; CFD analyses including wheel assembly, cooldown analyses, R13 repeated stop fade and alpine hot descent analyses for current design and new integrated rotor and hub pair for alternative ventilation vane designs. The analyses are especially focused on predicting the cooling period and predicting maximum bearing temperatures for normal and excessive loading scenarios. To provide benchmark a commercial integrated rotor and hub pair used in heavy duty vehicles is also analysed. The average convective heat transfer coefficient and cooldown period of proposed integrated brake rotor are improved by 117.3% and 30.5% compared to the base design. The maximum wheel bearing temperature is decreased by 27.0% and by 27.1% for the proposed integrated brake rotor and wheel hub compared to the benchmark model, in accordance with the repeated stop and alpine hot descent analyses. In addition, the total weight reduction of 10 kg (15%) according to the base design is achieved.

A study of the applications of a spring-assisted modular and reconfigurable robot for safe robot operation

A novel spring-assisted modular and reconfigurable robot (SA-MRR) has been recently developed at our laboratory to reinforce its performance, and to enable safe and dexterous operations in human environments. A power spring is inserted between the brake rotor and the motor shaft through a decoupling bearing. With the spring engaged, the working range of the joint is mechanically limited for safe operations, and such a limited working range can be established at any joint position. The safety aspect of the SA-MRR is investigated by operating the robot in a limited workspace created by activating the spring. The trajectory tracking capability of the SA-MRR is explored by comparing trajectories followed by a conventional MRR and SA-MRR in a restricted workspace, while lifting a heavy payload. Trajectory tracking is performed with various payloads to demonstrate the SA-MRR’s superior payload handling capacity performance due to addition of the spring-generated moment. These algorithms have been implemented on a 3-DOF SA-MRR and numerical simulations have been carried out to investigate the improved tracking accuracy and safety features due to addition of the spring-brake system.

A study of the applications of a spring-assisted modular and reconfigurable robot for safe robot operation

A novel spring-assisted modular and reconfigurable robot (SA-MRR) has been recently developed at our laboratory to reinforce its performance, and to enable safe and dexterous operations in human environments. A power spring is inserted between the brake rotor and the motor shaft through a decoupling bearing. With the spring engaged, the working range of the joint is mechanically limited for safe operations, and such a limited working range can be established at any joint position. The safety aspect of the SA-MRR is investigated by operating the robot in a limited workspace created by activating the spring. The trajectory tracking capability of the SA-MRR is explored by comparing trajectories followed by a conventional MRR and SA-MRR in a restricted workspace, while lifting a heavy payload. Trajectory tracking is performed with various payloads to demonstrate the SA-MRR’s superior payload handling capacity performance due to addition of the spring-generated moment. These algorithms have been implemented on a 3-DOF SA-MRR and numerical simulations have been carried out to investigate the improved tracking accuracy and safety features due to addition of the spring-brake system.

Laser Cladding Treatment for Refurbishing Disc Brake Rotors: Environmental and Tribological Analysis

In this study, grey cast iron disc brake rotors are refurbished by adding a surface layer through laser cladding. Current methods to deal with replaced rotors mainly include remelting, with a minority fraction disposed in landfill. Both approaches result in a huge waste of resources and an increase in CO2 footprint. From a sustainable point of view, this study aims to evaluate the feasibility of refurbishing brake rotors by a combined environmental and tribological performance approach. A streamlined life cycle assessment is conducted to compare the environmental impacts between producing virgin grey cast iron brake rotors and refurbishing replaced brake rotors by laser cladding. It turns out that the energy consumption and CO2 footprint of the laser cladding refurbished brake rotors are 80% and 90% less than the virgin brake rotors. The results show that the refurbished brake rotor yields higher friction compared to the original cast iron utilizing the same pad material. The wear and particle emissions of the disc brake contact are in this study higher for the laser-cladded one compared to the original cast iron one.

Laser cladding treatment for refurbishing disc brake rotors – environmental and tribological analysis

In this study, grey cast iron disc brake rotors are refurbished by adding a surface layer through laser cladding. Current methods to deal with replaced rotors mainly include re-melting, with a minority fraction disposed in landfill. Both approaches result in a huge waste of resources and an increase in CO 2 footprint. From a sustainable point of view, this study aims to evaluate the feasibility of refurbishing brake rotors by a combined environmental and tribological performance approach. A streamlined life cycle assessment is conducted to compare the environmental impacts between producing virgin grey cast iron brake rotors and refurbishing replaced brake rotors by laser cladding. It turns out that the energy consumption and CO 2 footprint of the laser cladding refurbished brake rotors are 80% and 90% less than the virgin brake rotors. The results show that the refurbished brake rotor yields higher friction compared to the original cast iron utilizing the same pad material. The wear and particle emissions of the disc brake contact are in this study higher for the laser cladded one compared to the original cast iron one.