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Fig7. Total deformation for the rotor without ceramic coating #Note: the brake system is front biased by 70% due to dynamic weight transfer during braking.

Fig7 7 Total deformation for the rotor without ceramic coating #Note: the brake system is front biased by 70% due to dynamic weight transfer during braking.

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Validation process is an important step ‘in this design optimization. The optimized model’s performance is compared with initial models. reduce product development time. Objective of this investigation is to reduce weight and wear of brake rotor system. This paper focuses on thermal and static analysis. Finite element analysis has been used to implement optimization and maintaining stress and deformation levels and achieving high stiffness. Reduction of weight has been one the critical aspects of any design along with reduction in deformation and stress factors, which increases the life of the product. It has a substantial impact on vehicle performance. The primary base material selected for the rotor is stainless steel due to its strength, hardness and corrosion resistance. Other materials like Cast iron and aluminum were also considered as alternatives initially but cast iron becomes too brittle if used in low thickness rotors and though aluminum dissipates more heat but it needs to be anodized with hard coat to withstand the deformations. Finally Hardened 420 stainless steel is chosen for its high strength to weight ratio and tensile strength, its availability in the local market also plays a prominent role.
Validation process is an important step ‘in this design optimization. The optimized model’s performance is compared with initial models. reduce product development time. Objective of this investigation is to reduce weight and wear of brake rotor system. This paper focuses on thermal and static analysis. Finite element analysis has been used to implement optimization and maintaining stress and deformation levels and achieving high stiffness. Reduction of weight has been one the critical aspects of any design along with reduction in deformation and stress factors, which increases the life of the product. It has a substantial impact on vehicle performance. The primary base material selected for the rotor is stainless steel due to its strength, hardness and corrosion resistance. Other materials like Cast iron and aluminum were also considered as alternatives initially but cast iron becomes too brittle if used in low thickness rotors and though aluminum dissipates more heat but it needs to be anodized with hard coat to withstand the deformations. Finally Hardened 420 stainless steel is chosen for its high strength to weight ratio and tensile strength, its availability in the local market also plays a prominent role.
Cee The zirconia-based ceramic coatings are used as thermal barrier coatings owing to their low conductivity and their relatively high coefficients of thermal expansion, which reduce the detrimental interfacial stresses.
Cee The zirconia-based ceramic coatings are used as thermal barrier coatings owing to their low conductivity and their relatively high coefficients of thermal expansion, which reduce the detrimental interfacial stresses.
CAD model of brake rotor was developed in 3D modeling software SOLIDWORKS, it consists of bolt holes for mounting, holes on surface for heat dissipation, out periphery is designed such that the stress concentration can be reduced and also for cleaning of pads. Rotor design mainly depends on caliper and the wheel- rim internal diameter. Fig. initial Model OF brake rotor An initial CAD model of rotor is modeled with a rotor thickness of 7 mm and rotor diameter of 240 mm. Takging the initial design as reference, a modified geometry with different layers of ceramic coating has been modeled. The new model has 5 layers where the first layer is of 350 um and the second layer is of 150 um and the third layer is of 6 mm and again the similar coating layers of similar thickness is followed on the other side of the third layer.
CAD model of brake rotor was developed in 3D modeling software SOLIDWORKS, it consists of bolt holes for mounting, holes on surface for heat dissipation, out periphery is designed such that the stress concentration can be reduced and also for cleaning of pads. Rotor design mainly depends on caliper and the wheel- rim internal diameter. Fig. initial Model OF brake rotor An initial CAD model of rotor is modeled with a rotor thickness of 7 mm and rotor diameter of 240 mm. Takging the initial design as reference, a modified geometry with different layers of ceramic coating has been modeled. The new model has 5 layers where the first layer is of 350 um and the second layer is of 150 um and the third layer is of 6 mm and again the similar coating layers of similar thickness is followed on the other side of the third layer.
Fig3. Patch showing five different layers
Fig3. Patch showing five different layers
Thermal And Structural Analysis Of A Ceramic Coated Fsae Brake Rotor Using 3d Finite Element MODEL AND NUMERICAL ANALYSIS
Thermal And Structural Analysis Of A Ceramic Coated Fsae Brake Rotor Using 3d Finite Element MODEL AND NUMERICAL ANALYSIS
Thermal And Structural Analysis Of A Ceramic Coated Fsae Brake Rotor Using 3d Finite Element
Thermal And Structural Analysis Of A Ceramic Coated Fsae Brake Rotor Using 3d Finite Element
Fig7. Total deformation for the rotor with ceramic coating Fig9. Equivalent elastic strain for the rotor without ceramic coating
Fig7. Total deformation for the rotor with ceramic coating Fig9. Equivalent elastic strain for the rotor without ceramic coating
Fig7. Von Mises stress for the rotor with ceramic coating
Fig7. Von Mises stress for the rotor with ceramic coating
Vil. UUNULUSIUN Optimization method used in this study in reducing the mass of brake rotor. Validation is done through finite element solver with the initial model and checked that maximum stress and displacement are within control. This optimization process also gives small change on the displacement and stress. The displacement and stress has significantly reduced in the new optimized design proving to provide better life of the product. Therefore, the overall weight of the rotor can be reduced by 10.11%, deformation by 74.11% and stress by 74.21%.
Vil. UUNULUSIUN Optimization method used in this study in reducing the mass of brake rotor. Validation is done through finite element solver with the initial model and checked that maximum stress and displacement are within control. This optimization process also gives small change on the displacement and stress. The displacement and stress has significantly reduced in the new optimized design proving to provide better life of the product. Therefore, the overall weight of the rotor can be reduced by 10.11%, deformation by 74.11% and stress by 74.21%.
Fig7. Equivalent elastic strain for the rotor with ceramic coating Thermal And Structural Analysis Of A Ceramic Coated Fsae Brake Rotor Using 3d Finite Element
Fig7. Equivalent elastic strain for the rotor with ceramic coating Thermal And Structural Analysis Of A Ceramic Coated Fsae Brake Rotor Using 3d Finite Element
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Mechanical EngineeringIndustrial DesignThermal Resistance
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