Design, Development and FE Thermal Analysis of a Radially Grooved Brake Disc Developed through Direct Metal Laser Sintering

Abstract

The present research work analyzed the effect of design modification with radial grooves on disc brake performance and its thermal behavior by using additive manufacturing based 3D printed material maraging steel. Temperature distribution across the disc surface was estimated with different boundary conditions such as rotor speed, braking pressure, and braking time. Design modification and number of radial grooves were decided based on existing dimensions. Radial grooves were incorporated on disc surface through Direct Metal Laser Sintering (DMLS) process to increase surface area for maximum heat dissipation and reduce the stresses induced during braking process. The radial grooves act as a cooling channels which provides an effective means of cooling the disc surface which is under severe condition of sudden fall and rise of temperatures during running conditions. ANSYS software is used for transient structural and thermal analysis to investigate the variations in temperatures profile across the disc with induced heat flux. FE based thermo-structural analysis was done to determine thermal strains induced in disc due to sudden temperature fluctuations. The maximum temperature and Von Mises stress in disc brake without grooves on disc surface were observed which can severely affect thermal fatigue and rupture brake disc surface. It was been observed by incorporating the radial grooves that the disc brake surface is thermally stable. Experimental results are in good agreement with FE thermal analysis. DMLS provides easy fabrication of disc brake with radial grooves and enhancement of disc brake performance at higher speeds and temperatures. Therefore, DMLS provides an effective means of implementing product development technology.

Initial Selection of Disc Brake Pads Material based on the Temperature Mode

“…Increasing the contact pressure to the value p 0 = 1.47 MPa significantly reduces the braking time: 37.1% (variant 4), 51.7% (variant 5), 68% (variant 6). Evolutions of the mean temperature T m (7) of the contact area of the pad with the disc are presented in Figure 6. Due to the same initial kinetic energy and, therefore, the total work done (Figure 4), the maximum values T m,max differ slightly for all considered calculation variants.…”

“…The difference between the highest 187.4 • C (curve 6b) and the lowest 160.6 • C (curve 4b) is equal to about 14.3% (Table 3). Evolutions of the mean temperature m T (7) of the contact area of the pad with the disc are presented in Figure 6. Due to the same initial kinetic energy and, therefore, the total work done (Figure 4), the maximum values ,max m T differ slightly for all considered calculation variants.…”

“…First, when the point of the rubbing path of the disc comes into contact with the pad, the temperature increases and reaches the maximum value, then after passing through the pad area, it decreases until another contact with the pad takes place. In the present analysis, the purpose was to find the change in the mean temperature of the contact region with respect to braking time defined by formula (7). That temperature was used in the construction of the computational model.…”

“…Thermo-structural analysis for conventional solid and grooved brake discs manufactured based on 3D printed of maraging steel was carried out in article [7]. The numerical calculations of temperature evolutions and von Mises equivalent stress fields in the discs were performed using ANSYS finite element method based software.…”

Thermo-Mechanical Coupling Analyses for Al Alloy Brake Discs with Al2O3-SiC(3D)/Al Alloy Composite Wear-Resisting Surface Layer for High-Speed Trains

“…The convection analysis data obtained from CFD simulation was directly imported into Solidwork2018 simulation software in the form of ‘fld’ format file as heat dissipation boundary conditions in thermal analysis [22]. As the stress was analyzed, the brake system components needed to be proper contact constraints.…”