Simulation and analysis of thermal and structural analysis on disk brake using CAE

Ab Halim, Muhammad Amir (2024) Simulation and analysis of thermal and structural analysis on disk brake using CAE. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

Text (Full Text) Simulation and analysis of thermal and structural analysis on disk brake using CAE.pdf - Submitted Version Download (4MB)

Abstract

Brakes serve the purpose of decelerating or halting a moving entity. During the braking process, kinetic energy derived from the velocity of the vehicle is transformed into thermal energy, causing an increase in the disc brake's temperature. To avoid damage to the disc brake or associated components, it is imperative to efficiently dissipate the generated heat into the surrounding atmosphere. One viable approach to enhance this heat dissipation is to augment the surface area exposed to the environment. This strategy is critical in maintaining the integrity and performance of the braking system. This study proposed 4 different profile of disc brake rotors based on dimension of Audi A6 ISO standard with combination ventilation features of groove and vent with different designs which are designed in CATIA. The materials is same for all of the disc brakes which is gray cast iron. The objectives are to model and simulate thermal analysis and structural analysis on the disc brake. Then, identify design modifications that can improve the performance of the disk brake in term of thermal and structure. The study used the transient thermal analysis and transient structural analysis in Ansys Workbench to simulate the performance of disc brake in term of heat distribution, heat dissipation, total deformation and distribution stress. Based on the analysis, the 4 profile disc brake rotors outperformed the base model in thermal performance but not in structural stability. Based on he comparison, Model 3 is the best proposed design in consideration of heat distribution, heat dissipation, total deformation and stress distribution.

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