Brake disc material analysis using pin and disc simulation

Rosman, Suhail Azmin (2022) Brake disc material analysis using pin and disc simulation. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

A brake is used in a vehicle to stop or slow down the vehicle. The brake works by creating a friction from the rubbing of the surface. The kinetic energy will transform into thermal energy and then the heat need to be dispersed. This act will slow down the vehicle until it stop. There are 2 types of brake system in vehicle which is drum brake and disc brake. This day, disc brake rise in popularity since disc brake is more efficient in stopping the vehicle. Many research has been made to find the best material for the brake disc. The material should be able to handle harsh environment, able to handle heat, and sturdy. The material should be long lasting to wear and long lasting. The material that often used in the brake material is gray cast iron and stainless steel. The gray cast iron are said to have good friction and wear performance while stainless steel is tolerant to almost all of the brake pad types. In this work, the performance of both Cast Iron and Stainless Steel was simulated using ANSYS Software. The design was based on the automobile disc brake and pad. The design was drawn on CATIA V5R20 and the file was saved to a types that is compatible to ANSYS Software. The test that was conducted is Steady State Thermal Analysis and Static Structural Analysis. From the result, it was found that, Stainless Steel is superior than Cast Iron. Cast Iron is slower in rising the temperature, but Stainless Steel has better heat flow and cooldown much faster. Stainless Steel also is more sturdy compared to Cast Iron. Stainless Steel deformed a lot slower and has better elasticity compared to Cast Iron. As a conclusion, the objectives for this project is achieved, which is to build a model to simulate brake disc and pad using CATIA V5R20. Next, to analyze the material of the brake disc its Structural and Thermal Analysis using ANSYS Software. Lastly, to determine the best material for brake disc and pad based on the analysis done.

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