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DESIGN AND ANALYSIS OF DISC BRAKEA PROJECT REPORTSubmitted ByDINESH Y 212712114036MURTHY R 212712114308PRAVEEN I 212712114311in partial fulfillment for award of the degreeofBACHELOR OF ENGINEERINGINMECHANICAL ENGINEERINGSRI VENKATESWARA COLLEGE OF ENGINEERINGSRIPERUMBUDURANNA UNIVERSITY: CHENNAI 600...

Description

DESIGN AND ANALYSIS OF DISC BRAKE A PROJECT REPORT Submitted By

DINESH Y

212712114036

MURTHY R

212712114308

PRAVEEN I

212712114311

in partial fulfillment for award of the degree of

BACHELOR OF ENGINEERING IN MECHANICAL ENGINEERING SRI VENKATESWARA COLLEGE OF ENGINEERING SRIPERUMBUDUR

ANNA UNIVERSITY: CHENNAI 600 025 APRIL 2016 i

ANNA UNIVERSITY: CHENNAI 600 025 BONAFIDE CERTIFICATE Certified that this project report “DESIGN AND ANALYSIS OF DISC BRAKE” is the bonafide work of DINESH Y,MURTHY R,PRAVVEN I who carried out the project work under my supervision.

SIGNATURE

SIGNATURE

Dr. K. PITCHANDI

Dr. M. PREM ANANTH

HEAD OF THE DEPARTMENT

SUPERVISOR

Professor

Associate Professor

Department of Mechanical Engineering

Department of Mechanical Engineering

Sri Venkateswara College Of Engineering

Sri Venkateswara College Of Engineering

Pennalur

Pennalur

Sriperumbudur – 602 117

Sriperumbudur – 602 117

Submitted for viva-voce held on _______________

INTERNAL EXAMINER

EXTERNAL EXAMINER

ii

ACKNOWLEDEMENT First and foremost we owe our heartfelt thanks to our parents for their blessings and their encouragement and support to do this project. We sincerely thank our principal Dr. S. GANESH VAIDYANATHAN, for giving us permission to carry out the project in our college. We express our sincere thanks to our Head of the department Dr. K. PITCHANDI, Department of Mechanical Engineering, for the constant encouragement given to us for carrying our project so as to gain practical knowledge in the field of study. We are grateful to Dr. M. PREM ANANTH Asst. Professor of Mechanical engineering our project guide his inspiration and motivation during the course of our project. We would like to express our sincere thanks to the faculty of Mechanical Engineering

department

of

SRI

VENKATESWARA

COLLEGE

OF

ENGINEERING for the facilities that we have availed during the course of our project. We would also like to thank our CAD LAB staffs for supporting in doing Design and Analysis work.

iii

ABSTRACT

The disc brake is a device used for slowing or stopping the rotation of the vehicle. Number of times using the brake for vehicle leads to heat generation during braking event, such that disc brake undergoes breakage due to high Temperature. Disc brake model is done by CATIA and analysis is done by using ANSYS workbench. The main purpose of this project is to study the Thermal analysis of the Materials for the carbon, Cast Iron, and stainless steel. A comparison between the three materials for the Thermal values and material properties obtained from the Thermal analysis, low thermal gradient material is preferred. Hence best suitable design, low thermal gradient material cast iron is preferred for the Disc Brakes for better performance.

iv

LIST OF FIGURES S.NO

TITLE

PAGE.NO.

1.1

Simplified Schematic of a Disc Brake System

3

1.2

Detailed CAD Model of a Disc Brake

4

Drum brake

4

Flow chart of material selection method.

7

Drafting of disc brake using cadia:

25

1.3

3.1 8.1

8.2

26 Assembly drawing of disc brake:

8.3

Modal analysis of disc brake: carbon material

8.4

Static structural analysis: carbon materials

28

35 8.5

Steady state thermal analysis: carbon materials

39

42 8.6

Modal analysis : cast iron

8.7

Structural analysis : cast iron v

46

8.8

Steady state analysis: cast iron

8.9

Modal analysis : stainless steel

48

52

8.10

8.11

Static structural analysis: stainless steel

Steady state thermal analysis: stainless steel

vi

56 Steady state 58

TABLE OF CONTENTS CHAPTER

TITLE

PAGE NO.

ACKNOWLEDGEMENT

iii

ABSTRACT

iv

NO.

1.

2.

LIST OR FIGURES

v

INTRODUCTION

1

1.1 Introduction to braking system

1

1.2 Motor cycle applications

2

1.3 Types of brakes

2

1.3.1 Disc brakes

2

1.3.2 Drum brakes

4

1.3.3 Anti lock brakes

5

1.3.4 Air brakes

5

MATERIAL REQUIREMENT FOR DISC BRAKE

5

vii

3.

STAGES OF MATERIAL SELECTION

6

4.

BASED ON MATERIAL SELECTON

7

4.1 Carbon materials 4.1.1 Carbon material properties 4.1.2 Advantages and disadvantages 4.2 Cast iron materials 4.2.1 Properties 4.2.2 Applications 4.2.3 Advantages and disadvantages

7 8

5.

6.

7.

8

4.3 Stainless steel 4.3.1 Properties

9 10 11 12 12 14

BRAKE PADS

15

5.1 Material selection 5.2 Types of brake pads POSSIBLE DISC DAMAHE MODE 6.1 Wrapping 6.2 Scarring 6.3 Cracking THEORITICAL FORMULA FOR DISC BRAKE

15 15 17

viii

17 18 18 18

8.

INTRODUCTION TO CATIA

22

9.

RESULTS

61

10.

9.1 Carbon material 9.2 Cast iron material 9.3 stainless steel material CONCLUSION

61 62 63 65

11.

REFERENCES

66

ix...