Vivek[2]
International Research Journal of Engineering and Technology (IRJET) e ISSN: 2395 0056 Volume: 08 Issue: 12 | Dec 2021 www.irjet.net p ISSN: 2395 0072 © 2021, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page1582 Design and Analysis of Conventional and Perimetric Disc Brake Kaustubh Khanvilkar1 , Bhushan Mahajan2 , Lekha Bhatt3 1,2,3UG Student Mechanical Engineering Department, Terna Engineering College, Navi Mumbai *** Abstract -
Perimetricdiscisboltedthroughitsouterperimeterandthe calipersaremountedfromtheinnerperimeterofthedisc. Thisisdonesothatalargersizedisccanbeaccommodated andalessertorquehastobeworkedupon.Aperipheraldisc brake needs less brake force for same effects, induce the remainingbendingandshearstressesinwheelspokesand lessradial thrustatthewheel bearing.All ofthesefactors allowforalightweightofthewheel.Lighterweightmeans moreefficiency,reducingunsprungmassandahigherpower toweightratio.
In 21st century brake designing is an important task and companies are constantly updating and improving their designs which are safer for passengers and are quick in their response. There are some important parameters that are considered while evaluating braking performance of a vehicle which include deceleration, stopping distance and the time required to stop. This paper tries to present a new approach to designing a brake disc for two wheelers which reduces stopping distance and time with less efforts made by the rider. The performance of this disc is compared with the existing bike brake disc. Static structural and thermal analysis has been carried out on the conventional and perimetric disc to determine changes in deformation and stress along with temperature. Software’s like Solidworks, Ansys have been used to design and analyze the components. After the analysis it was evident that the proposed new design was more efficient than the conventional design and had better results in all the parameters that it was tested for Key Words: Perimetric Disc, Ansys, Solidworks, Brake Distance, Deformation, Stress
2. LITERATURE REVIEW
Tanuj[1]Joshietalconductedastudyonperimetricbrakedisc andconcludedthatperimetricbrakediscwasmuchbetter thanconventionalbrakediscasitincreasedthedeceleration ofvehicle,decreasedstoppingdistanceofvehicle,decreased thestoppingtimeandwasstructurallyandthermallysafe.
1. INTRODUCTION
It was observed that peripheral disc brakes needed less brake force for producing the same end effect, and they inducelesserbendingandshearstressinwheelspokesand alsoverylesserradialthrustatthewheelbearings.Thusall thesefactorsallowformakingaverylightweightmotorcycle front wheel. Having less weight means more efficiency, reducedunsprungmassandahigherpowertoweightratio.
Whenitcomestomanufacturinganyvehiclebrakesarea crucialpartofthesystemandthusalotofattentionisgiven totheproblemsassociatedwithit.Drumbrakesanddisc brakesarethemajorityofthebrakesusedtodaywithdisc brakesbeingmoreefficientbutcostlythandrumbrakes.A discbrakeconsistsofbrakecalipersthatsqueezethepairof padsagainstthe rotating brakedisc and withthehelpof frictionthespeedofrotationisreduced.Theyarebetterat managing heat and since they are open to environment convectioncanoccureasilybecauseofthislessbrakefade occursandconsistentbrakingisobtained.Thebrakepads arefoundtolastlongerthanthebrakeshoesinthedrum brakes.Thediscbrakingsystemissimpleandeffectivein itsoperationthisleadstoeasyreplacementofthedamaged parts.Howevertherearecertainproblemsassociatedwith them like brake howl, brake judder and longer braking distance.Perimetricbrakediscisanewconceptthataims to reduce such issues and simultaneously improve the existingqualitiesofdiscbrake.
A. Kamble et al in their experimentation found out those perimeter disk brakes provide larger braking radius,lessbrakingdistance,relativelylessslippercentage andmoresurfaceareafordissipationandbetterstabilityas comparedtoconventionaldiskbrakes.[3] Ms. A. J. Padwal et al designed an approach to resolve the varianceofthedesignspacewithoutdisturbingthedesignof thewheelrimandtheexperimentationwascarriedouton Pulsar150ccbike’sfrontwheel.Fromtheanalysisofboth perimetric and conventional disc it was found out the stresses and temperature induced in the perimeter brake systemaremuchlessascomparedtotheconventionaldisc brake system and thus it was understood the time and distance required to stop the vehicle in the perimetric system waslesswiththesame efforts in the conventional system.[4] Brake noise is caused due to the vibrations of the brake during braking. If the friction force between friction pads andbrakediscvariesthenitcancausebrakediscstovibrate atdifferentfrequenciesandalsomakebrakenoise.Inthis papertheBrakeTorqueVariation(BTV)isconsideredbythe author the main reason for the vibrations produced. The author suggests changing of friction plate and structure
International Research Journal of Engineering and Technology (IRJET) e ISSN: 2395 0056 Volume: 08 Issue: 12 | Dec 2021 www.irjet.net p ISSN: 2395 0072 © 2021, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page1583 designalongwithcarefulselectionofbrakefrictionpartsto attenuatethebrakenoises[5]. 3. ANALYSIS METHODOLOGY Modeling of brake rotor Theconventionalandperipheralbrakerotormodelforthe front wheel was completely designed on Solidworks. The sketch command was used to design a 2d sketch by using various geometrical commands. Then the sketch was convertedinto3Ddesignbyextrudecommandandvarious otherfeatureswereaddedtothediscmodel Meshing A finite element based software ANSYS is used. The discretized FEA models of the conventional disc and peripherydiscareshowninFig.1andFig.2,respectively.It contains31516nodesand12464elementsontheperipheral rotor and 81691 nodes and 56623 elements on the conventionalrotor Design Specifications Forthisstudy,the Yamaha R15bike wasselectedandthe followingtableshowsthespecificationofthebrakingsystem [2,6] Table -1: Specifications Parts (conventional)Front (Perimetric)Front Master Cylinder Diameter 11 11 Piston Caliper Diameter 25.40 (Dual Piston) 25.40 (Single Piston) Pedal Ratio 5:1 5:1 Tire Diameter 575.9mm 575.9mm Disc Diameter 267mm 380mm Disc Thickness 4mm 4mm External Diameter of Rubbing Surface 265mm 380mm Internal Diameter of Rubbing Surface 210mm 325mm Friction Length of Pads 61.5mm 61.5mm Number of pads 2 2 Caliper 1 1 Fig 1:ConventionalDisc Fig 2:PerimetricDisc 4. CALCULATION Thegoverningcalculationsrequiredtoperformtheanalysis aregivenasfollows: Externalparametersrequiredforthecalculationsare: InitialVelocity=120kmph=33.33m/s2 StoppingDistance(s)=100m Massofvehiclealongwithdriver=200kg v=InitialVelocity(m/s) u=FinalVelocity(m/s) a=Acceleration(m/s2) t=Time(seconds) T=TotalTime(seconds) K.E1=KineticEnergyInitial(J) K.E2=KineticEnergyFinal(J) W=WorkDone(J) UsingNewtonsLawsofmotion,CalculatingDeceleration(a): 2as=v2 u2 2*a*100=33.32 02 a=5.55m/s2 Calculatingstoppingtimetaken(t) v=u+a*t 0=33.33 5.55*t t=6sec For Conventional Front Disc Braking force (Fb) K.E2 K.E 1=W 12*0.72M×V2 =Fb*s….(Brakebiasis72:28) Fb =799.84N Torque required to stop the wheel (T) T=Fb *radiusofwheel T= T=229.954799.84*(0.575)/2Nm Force on Brake Disc (Fd) Fd=T/(radiusofdisc*µ)…...(µpads=0.4) Fd =4306.25N Pressure created by piston (P) A=Areaof1pistoncaliper P=F/2A P=4.249MPa
International Research Journal of Engineering and Technology (IRJET) e ISSN: 2395 0056 Volume: 08 Issue: 12 | Dec 2021 www.irjet.net p ISSN: 2395 0072 © 2021, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page1584 Force applied by master cylinder to get the required pressure (Fc) A=Areaofmastercylinderpiston Fc=P*A Fc=403.81N Sincethepedalratiois5:1 The force applied by human (Fh) Fh =(Fc*1)/5 Fh =80.76N Meanrighthandbrakeforcebyhumansis78.66N[7] For Perimetric Front Disc Braking force (Fb) K.E2 K.E 1=W 12*0.72M*V2 =Fb*s Fb =799.84N Torque required to stop the wheel (T) T=Fb *radiusofwheel T= T=229.954799.84*(0.575)/2Nm Force on Brake Disc (F) F=T/(radiusofdisc*µ)…...(µpads=0.4) F=229.954/(0.19×0.4) F=3025.71N Pressure created by piston (P) A=Areaof1pistoncaliper P=F/2A P=3025.71/(2*506.707) P=2.985MPa Force applied by master cylinder to get the required pressure (Fc) A=Areaofmastercylinderpiston Fc=P*A Fc=283.68N Sincethepedalratiois5:1 The force applied by human (Fh) Fh=283.68/5 Fh=56.73N Meanrighthandbrakeforcebyhumanis113.46N[7]. 4.1 Material MaterialusedforfrontdiscisCastIronasitischaracterized for its efficient thermal conductivity and anti vibration capacity.FollowingarethepropertiesofCastIron[8] Table 2: MaterialsProperties Material Properties Values Density 7.15E 06kg/mm3 Young'sModulus 120500MPa Poisson'sRatio 0.3 YieldStrength 758MPa ThermalConductivity 0.021W/(mmK) ThermalExpansionCoefficient 1.2E 05/K SpecificHeat 450(kgK) 4.2 Operating Conditions Theoperatingparametersforthestudyaresetaccordingto theTable 3: Table 3: Operatingconditions Temperatureambient 20°C Stoppingtime 7seconds Convectionvalue 38W/(m2 K) Gravity 9.81 /s2 5. ANALYSIS Staticandthermalanalysiswereperformedonthemodelsof the brake discs using the calculated forces and pressure applied on the discs,material andoperatingconditions as giveninTable2 andTable3 5.1 Static structural analysis Staticanalysisisperformedoverastructuretocheckifitcan withstandtheappliedexternalloadsunderstaticconditions. During the analysis loads and boundary conditions are appliedgradually. SolvingModel TotalDeformation VonMisesStress Fig 3:TotalDeformationofconventionaldisc Fig 4:Equivalent(von Mises)stressforconventionaldisc
The vehicle was assumed to be moving at a speed of 120 before applying the brakes. To comprehend the deformationand developedinboththetypeof modelsaftertheapplicationof andpressure,astatic analysis was performed on Ansys software. A force of 4306.25N and pressure of 4.38MPa was applied on the conventional whileaforceof3025.71Nandpressureof 2.98MPawasappliedontheperimetric
disc
kmph
disc.
forces
stresses
disc
International Research Journal of Engineering and Technology (IRJET) e ISSN: 2395 0056 Volume: 08 Issue: 12 | Dec 2021 www.irjet.net p ISSN: 2395 0072 © 2021, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page1585 Fig 5:TotalDeformationofPerimetricdisc Fig -6:Equivalent(von Mises)stressforPerimetricdisc 5.2 Thermal analysis: Thermalanalysisisperformedtodeterminewhateffectwill be observed on the model surface under extreme temperatureandpressurebyassigningthemodelrequired Solvingconstraints.Model TemperatureChange HeatFlux Fig 7:Temperatureforconventionaldisc Fig -8:Totalheatfluxforconventionaldisc Fig 9:Temperatureforperimetricdisc Fig 10:Totalheatfluxforperimetricdisc 6. RESULTS
[8] G.RanjithKumar,S.Thriveni,M.RajasekharReddy,Dr.G. HarinathGowd4,“DesignAnalysis&Optimizationofan AutomotiveDiscBrake”.(IJAERS).Vol 1,Issue 3,Aug 2014.
[3] Vivek A. Kamble, Arun Kumar Battu, “Design DevelopmentAnalysisand PerformanceEvaluation of PerimeterBrakesinTwoWheeler”,IJSRD International Journal forScientific Research&Development|Vol.5, Issue07,2017.
[4] Ms. A. J. Padwal, Prof. A. R. Patil, Prof. D. Kumar, “DESIGN, ANALYSIS AND CHARACTERIZATION OF PERIPHERALDISCBRAKESYSTEMFORMOTORCYCLE FRONT WHEEL”, IJARIIE ISSN (O) 2395 4396 Vol 5 Issue 42019.
International Research Journal of Engineering and Technology (IRJET) e ISSN: 2395 0056 Volume: 08 Issue: 12 | Dec 2021 www.irjet.net p ISSN: 2395 0072 © 2021, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page1586 Table 4: Conclusionofthestudy Parameter Conventional Perimetric Max Min Max Min Deformation 0.32mm 0 0.0033mm 0 Von Mises Stress 412.06MPa MPa0.648 MPa12.865 MPa0.08 Temperature 200.5°C 128.5°C 200.15°C °C183.28 HeatFlux 3.15E W/mm02 2 W/mm097.77E2 4.68E 02 W/mm2 W/mm084.56E2 7. CONCLUSIONS Thestudyinthispaperhasshownthattheuseofperimetric disc instead of the conventional disc results in less requirementofthehumanefforttostopthevehicleandalso thedistancerequiredforstoppingreduces.Theperimetric disc has less deformation and stresses under the applied load which leads to more lifespan of the disc. Perimetric brake disc can be a good alternative to the conventional discsbecauseoftheirlargerradiusandmoresurfaceareafor heat dissipation ultimately giving better stability during braking. 8. REFERENCES [1] ShivankurMittal,“PeripheralDiscBrakeSystemandits Comparison with Conventional Disc Brake System for useinMotorcycleFrontWheel”,InternationalJournalof AerospaceandMechanicalEngineeringVolume3 No.4, August2016. [2] Tanujjoshi,SharangKaul,“DesignandOptimizationof Perimetric brake disc rotor”, International Journal of Scientific & Engineering Research Volume 7, Issue 8, August 2016ISSN2229 5518.
[7] Saiprasit Koetniyom, Manus Dangchat, Songwut Mongkonlerdmanee, Julaluk Carmai, and Sunarin Chanta,“IdentificationofHandbrakePatternsofYoung MotorcycleRidersinThailandUsingaNewlyInvented Force Measuring Device”, ENGINEERING JOURNAL, Volume22Issue5,2018.
[5] LiJin,XuJianchang,LuoFang,“ResearchonBrakeNoise of Air Disc Brake”, Third International Conference on Measuring Technologyand MechatronicsAutomation, 2011. [6] “Fmsci TheFederationofMotorSportsClubsofIndia” 2012,2WTechnicalDataFormNo.TDF 212MC002, YamahaYZFR15v2.0.