Topological Optimization of Automobile Rotor Disk Brake

International Journal of Mechanical Engineering

© 2019 by SSRG - IJME Journal

Volume 6 Issue 4

Year of Publication : 2019

Authors : Vipul Matariya, Hiren Patel

10.14445/23488360/IJME-V6I4P105

How to Cite?

Vipul Matariya, Hiren Patel, "Topological Optimization of Automobile Rotor Disk Brake," SSRG International Journal of Mechanical Engineering, vol. 6,  no. 4, pp. 23-27, 2019. Crossref, https://doi.org/10.14445/23488360/IJME-V6I4P105

Abstract:

An automobile disk brake is an essential mechanical system used to slow down and stop the vehicle. During the operation of the brake, a high amount of kinetic energy will generate a high amount of heat energy and forces. The generated heat increases the rotor temperature, which leads to disk brake rotor deformation due to the combined effect of mechanical forces and temperature. During the study, a disk brake rotor will be investigated for frictional forces acting on it and heat generated due to friction between calliper pads and rotor surface. Brake rotor dimensions can be optimized for strength with a reduction in weight using advance topology optimization method. Topology optimization is very useful engineering technique, especially at the concept design stage. Topology optimization is able to produce reliable and satisfactory results with the verified structural model. Topological optimization will be performed on ANSYS 18.1 software. New disk brake rotor shape will be produced with the Creo 3.0 based on the topology optimization result. The new disc brake rotor from a topology optimization result will compare with the traditional concept model and topology optimization base model. It will analyze that a new rotor will not fail during an experiment test, and these results will be verified with a fabricated real sample under the durability condition.

Keywords:

Disk brake, Ceramic materials, ANSYS, Topological optimization

References:

[1] Chogdu C and Sooick A, "Thermo-Elastic Analysis for Chattering Phenomenon of automotive disk brake", KSME Inter. J., 2001, 15, 569-579.
[2] Thira J.and Daniel H, "Disk Brake Squeal: Modelling and Active Control", Diploma Thesis, T.U. Darmstadt, Institute f¨urMecha, 2003.
[3] Introduction to Brake Systems – Study Guide, Melior General Motors Corporation, Service Operations License Agreement, 2004.
[4] Pandya NA, "Computer-Aided Design and Analysis of Disc Brake Rotors Advances in Automobile Engineering,"BITS Pilani, Dubai Campus, Dubai International Academic City (DIAC), Dubai, U.A.E. Amrish, AdvAutomobEng, 2016, 5:2.
[5] Swapnil R. Abhang, Bhaskar D.P., "Design and Analysis of Disc Brake", Inter. J. of Engin. Trends and Techn. (IJETT) –4- Feb 2014
[6] Phillip H. and Nick w. "Materials of brake pads", https://auto.howstuffworks.com/auto-parts/brakes/brake-types/disc-brake.htm
[7] Ibrahim RA, "Friction-Induced Vibration", Chatter, Squeal and Chaos Part II, ASME Applied Mechanics Reviews, 47, 1994, 227-259.
[8] Chakraborty G, Jearsiripongkul T, Wagner UV and Hagedorn P,”A New Model for Floating Calliper Disk Brake”, VDI-TagungReibung and Schwingungen in Fahrzeugen und Anlagen, Hannover, November 26-27, 2002.
[9] Chowdhary HV, Bajaj AK and Krousgrill CM, "An Analytical Approach to Model Disc Brake System for Squeal Prediction", Proceedings of ASME DETC 2001, Pittsburgh, September 9-12, 2001.
[10] Ouyang H and Mottershead J.E., "Friction-Induced Parametric Resonances in Disc: Effect of A Negative Friction-Velocity Relationship", J. of Sound and Vibration, 209(2), 1998, 251-264.
[11] Lin SC, Guan CC, Bakar A.R.A., Jamaluddin MR, M.M.W. Harujan W, and Ghani BA, "Disc brake squeal suppression through chamfered and slotted pad." Intern. J. of Vehicle Struc. And Syst., 3(1), 2011, 28–35.
[12] Dai Y and Lim TC, "Suppression of brake squeal noise applying finite element brake and pad model enhanced by spectral-based assurance criteria", Applied Acoustics, 69(3), 2008,196 – 214.
[13] Ghazaly NM and Faris WF, "Optimal design of a brake pad for squeal noise reduction using response surface methodology", Inter. J. of Vehicle Noise and Vibration, 8(2), 125–135, 2012.
[14] Eriksson M, Bergman F, and Jacobson S, "On the nature of tribological contact in automotive brakes", Wear, 252(1-2), 2002, 26–36.
[15] Lee K and Barber J.R., "An experimental investigation of frictionally excited thermoelastic instability in automotive disk brakes under a drag brake application", J. of Tribology, 116(3), 1994, 409–414.
[16] Hiller MB, "Correlation between parameters of the tribosystem and automotive disc brake squeal", PhD thesis, University of Paderborn, 2006
[17] Matzo L, Menetrier A, and Tamagna A. Analysis of high damping underlayer materials for brake pads and its effects on NVH performance. S.A.E. Technical Paper, pages 01–3223, 2006.
[18] Automotive Disc Brake Manual: The Complete Guide to the Theory and Practice of Automotive Disc Braking Systems. Techbook Series. Haynes, Somerset, 1998.
[19] Matzo L, Menetrier A, and Tamagna A, "Analysis of high damping underlay materials for brake pads and its effects on NVH performance", S.A.E. Technical Paper, 01–3223, 2006.
[20] Automotive Disc Brake Manual: "The Complete Guide to the Theory and Practice of Automotive Disc Braking Systems", Tech book Series. Haynes, Somerset, 1998.
[21] Balvedi AM and Gerges SNY, "Squeal noise in disc brakes and the influence of damping on the system dynamic stability", ActaAcustica united with Acustica, 94(2), 2008, 254–264.
[22] Kinkaid OM, Reilly O and Papadopoulos P, "Automotive disc brake squeal", J. of Sound and Vibration, 267(1), 2003, 105–166.
[23] Chan D and. Stachowiak GW, "Review of automotive brake friction materials", Proc. of Inst. of the mech. Engin., Part D: J. of Automobile Engin. 218(9), 2004, 953-966.
[24] Hong US, Jung SL, Cho KH, Cho MH, Kim SJ, and Jang H, "Wear mechanism of multiphase friction materials with different phenolic resin matrices wear", 266 (7-8), 2009, 739- 744.
[25] Fu Z, Suo B, Yun R, Lu Y, Wang H, Qi S, Jang S, Lu Y, and Matejka V, "Development of eco-friendly brake friction composites contain flax fibres", J. of Reinf. Plastics and Composites, 32(10), 2012, 681-689.
[26] Jang H, Ko K, Kim SJ, Basch RH, and Fash JW, "The effect of metal fibres on the friction performance of automotive brake friction materials", Wear, 256(3- 4), 2004, 406 – 414.
[27] Blau PJ, "Compositions, functions, and testing of friction brake materials and their additives", Tech. Report No. ORNL/TM-2001/64, Oak Ridge National Lab., TN (U.S.), 2001.
[28] Oberst S, Lai J.C.S., "Statistical analysis of brake squeal noise", J. of Sound and Vibration 330(2011"), 2978–2994.
[29] Jearsiripongkul T, Hochlenert D, "Disk brake sequel: Modelling and active control", RAM 2006, IEEE.
[30] C.Akshay, B.Adesh, Suresh Vellingiri, "Design & Analysis of Disc Brake System" SSRG International Journal of Mechanical Engineering 5.11 (2018): 27-29.
[31] Ameer S. and Lakshmi S, "Structural and Thermal Analysis of Disc Brake Without Cross-drilled Rotor Of Race Car", Inter. J. of Advan. Engg. Rese. and Studies, 2012, 2249-8974, 39-43