Thermal-Stress Analysis Of Cross-Drilled Disc Brake Rotor For UTeM Formula Style Race Car

Loo , Chooi Heng (2011) Thermal-Stress Analysis Of Cross-Drilled Disc Brake Rotor For UTeM Formula Style Race Car. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

Formula Varsity is an event organized by Universiti Technikal Malaysia Melaka. In the process of designing the car, brake system is one of the major components. Disc brake rotor generates an opposite torque to a shaft, converting kinetic energy to heat energy. To better understand the design limit of the rotor, simulation and manual calculation methods were employed in order to find temperature distribution on rotor and thermal capacity of the rotor and stress induced to the rotor due to the braking heat. In this PSM report, for the method of manual calculation, all the environment data has been collected during the testing event and race event. Besides, there are a few assumption also made in the manual calculation method. The result of the calculation is tabulate and present in the graph form for better understand. For the part of simulation method, the software of ABAQUES will use to do the Finite Element Analysis (FEA) process. With the aid of the FEA software, it will show us the right distribution of temperature and stress on the rotor. At the end of the project, the result of the manual calculation and result of simulation will being compared and validated. The maximum surface temperature was found to be 547ºC and 541 ºC for manual calculation and FE analysis respectively. The maximum stress obtain from manual calculation is 1.49 MPa, while the maximum stress obtain from FE analysis using ABAQUS is 0.82 MPa The results show that the rotor is safe for operation after 10 cycle transient braking test.

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