FABRICATION AND COMPUTATIONAL ANALYSIS … of aluminium composites in the current years. ... Fly ash particle used in current work is ... application and the demand for lightweight

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International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 6, June 2017, pp. 553–563, Article ID: IJMET_08_06_058

Available online at http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=6

ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication Scopus Indexed

FABRICATION AND COMPUTATIONAL

ANALYSIS OF CENOSPHERE REINFORCED

ALUMINUM METAL MATRIX COMPOSITE

DISC BRAKES

R. Kousik Kumaar

Assistant Professor, Department of Aeronautical Engineering,

Nehru Institute of Technology, Coimbatore

G. Kannan


Veltech Dr.RR & Dr.SR University, Chennai

G. Boopathy

Associate Professor, Department of Aeronautical Engineering,


G. Surendar



ABSTRACT

The disc brakes which replaced drum brakes, has found great performance in the

automobile industries and also found a prominent role in the aeronautical/aerospace

industries. In recent research, composites are used because of low weight and high

thermal performances. To moderate the structural weight and progress in fuel

efficiency, the aeronautical/automobile industry has melodramatically increased the

use of aluminium composites in the current years. Aluminium alloy based metal matrix

composites (MMCs) reinforced with ceramic particulates have publicized great usage

for such applications. Moreover, these advanced materials have the potential to

perform better under severe conditions like higher speed, higher load etc. which are

increasingly being encountered. In this study an effort, has been made to investigate a

new composite material called cenosphere reinforced aluminium alloy. The

Aluminium-Cenosphere composite material which has low thermal expansion and

greater performance in hot and cold conditions can be used in the disc brake.

Repetitive braking of the vehicle leads to wear on both brake pad & disc surface

during each braking event. The resulting wear has very significant role in the

performance of the braking system. The objective of this study is to analyze disc brake

system, to simulate disc brake assembly and to prepare the FEM model for contact

analysis. A three-dimensional finite element model of the brake pad and the disc is

Fabrication and Computational Analysis of Cenosphere Reinforced Aluminum Metal Matrix

Composite Disc Brakes


developed to calculate static state analysis and transient state analysis. Properties of

numerical model are set from properties of cenosphere reinforced aluminium matrix

composite. The major FEM analysis like stress and thermal analysis is performed.

Key words: Aluminium-Cenosphere composite material, Stress Analysis, Thermal

Analysis.

Cite this Article: R. Kousik Kumaar, G. Kannan, G. Boopathy and G. Surendar.

Fabrication and Computational Analysis of Cenosphere Reinforced Aluminum Metal

Matrix Composite Disc Brakes. International Journal of Mechanical Engineering and

Technology, 8(6), 2017, pp. 553–563.

http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=6

1. INTRODUCTION

Conventional monolithic materials have limitations with respect to achievable combinations

of strength, stiffness and density. In order to overcome these shortcomings and to meet the

ever-increasing engineering demands of modern technology, metal matrix composites are

gaining importance. In recent years, discontinuously reinforced aluminium based metal matrix

composites have attracted worldwide attention as a result of their potential to replace their

monolithic and counterparts primarily in aerospace, automobiles energy sector. [1]

The present investigation has been focused on utilization of waste fly ash particle in useful

manner by dispersing it in aluminium matrix to produce composite. In the present work, fly

ash particle which mainly consists of refractory oxides like silica, alumina and iron oxides

will be used as the reinforcing phase and to increase the wettability, magnesium or silicon

were added. Fly ash particle used in current work is called as cenosphere or micro balloon. It

is a hollow sphere made up of ceramic outer surface. Cenospheres as a filler in Al casting

reduces cost, decreases density and increase hardness, stiffness, wear and abrasion resistance.

It also improves the maintability, damping capacity, coefficient of friction etc, which are

needed in various industries like aerospace, automotive etc.

The basic idea is that continuous fiber reinforced composite has better strength but the

processing methods is highly expensive which hinders their adoption. The continuous fiber

reinforced composites do not allow secondary forming such as rolling, forging and extrusion.

As a result of these limitations new efforts on the research of discontinuous reinforcements

have been used at early stages of development of metal matrix composite emphasis on the

preparation of fiber reinforced composite only. But due to the high cost associated with the

process of production, anisotropic properties of the resultant composite and difficulties

associated with the fabrication process, production of this type of composite has been limited.

Now-a-days the particulate reinforced Aluminium matrix composite are gaining importance

because of their low cost with advantage like isotropic properties. The strengthening of

Aluminium alloys with dispersion of fine ceramic particulate composite materials were

developed as an alternative of unreinforced alloy for obtaining materials with high stiffness

(high strength/modulus and low density) with special interest for the structural applications.

The dispersion strengthened alloys can be classified, based on the size and volume percentage

of particles uniformly dispersed in the matrix. [2-5]

The braking capacity of the disc brakes is more efficient than the ordinary drum brakes.

So, the aircraft requires a halt on the runway which may be shorter at some times at high

velocity approaching the ground. In recent criteria, composites are used because of low

weight and high thermal performances. CMC-Ceramic Matrix Composites are used in the disc

brake rotors which has low density with increased strength and tribological characteristics.

R. Kousik Kumaar, G. Kannan, G. Boopathy and G. Surendar


Due to its low coefficient of thermal expansion and high thermal conductivity, this CMC can

retain its strength at high temperature. [6]

The CMC disc brakes are very expensive and they become inefficient and much weaker if

used in cold conditions. The weakness is a result of thermal expansion of the composite and

ceramic matrix. As the material expands at different rates under different temperatures

cracking can occur on the surface. It was found that with this ceramic composite certain area

wouldn’t dissipate heat resulting in “hot spots”. This is due to the materials ability to conduct

heat in axial and transverse directions. Since the fibers are placed perpendicular to the friction

surface they are unable to transfer heat in other directions. The simplest solution is to make

the material with a higher ceramic content. This sacrifices the strength of the brake and while

adding excess mass, since the density of ceramic is far greater than the composite fiber.

Another solution is to use a more thermally conductive fiber in the ceramic matrix. This

results in a higher cost of production. [7-8]

Instead of this CMC brakes, brakes made out of AMC has better performances compared

with CMC. The Aluminium-Cenosphere composite material can be used in the disc brake

rotors and the performance can be analyzed, which has low thermal expansion and greater

performances in hot and cold conditions.

2. METHODOLGY

2.1. Stir Casting of Aluminium Metal Matrix Composite

Stir casting is a unique and prominent technique for the development of reinforced aluminium

matrix composite materials. This technique is utilized as a result of its simple process and

ability to overcome the problem of expensive processing method which has restricted the

widespread application of metal matrix composite which are considered potential material

candidate for various structural and nonstructural applications in the field of aerospace,

automotive, biomedical, military defence and sports industries. The development of this

promising technique evolved as a result of modern technological advancement in material

application and the demand for lightweight materials with improved mechanical and thermal

properties. This process involves a liquid state fabrication technique which requires the

incorporation of reinforcing phase (discontinuous form) into a molten matrix metal

(continuous form) to obtain a uniform distribution through stirring as shown in Fig.1.

Figure 1 General Stir Casting Setup




2.2. Procedure for Stir Casting

Aluminium alloys reinforced with ceramic particles exhibit superior mechanical properties to

unreinforced aluminium alloys and hence are candidates for engineering applications. The

aluminium metal matrix composites are produced either by casting route or by powder

metallurgy. The former has the advantage of producing the component at lower cost and

possibility of producing larger components. However, the inherent difficulties of casting

difficulties are non-wettability of ceramic particles by liquid aluminium, segregation of

particles higher porosity level and extensive inter - facial reaction due to higher processing

temperature. Wettability of the particles can be improved by coating the particles with metals

such as Ni and Cu, addition of active elements such as Si and Mg into liquid Al or preheating

of the particles before addition into liquid aluminium. The most conventional method of

production of composites by casting route is vortex method where the liquid aluminium is

stirred with an impeller and ceramic particles are incorporated into vortex formed by stirring

of the liquid metals. Addition of Si or Mg into the liquid metal reduces the surface tension and

there by avoids the rejection of the particles from the melts. Hence 2% - 6% of Si or Mg is

generally added into the Al melts before incorporation of the particles. [9-10]

2.3. Simple Casting Setup

The casting setup used in the process of casting aluminium – cenosphere composite material

is based upon the Stir casting technique. The Stir casting method is the process of

implementing an impeller at a specified rpm for the fine dispersion of the cenosphere in the

molten metal of aluminium alloy.[11-13] The main equipment used in fabricating aluminum –

cenosphere composites specimen are: Stirrer, Temperature controller, Pre-heater and Furnace.

The total assembly is shown in the Fig.2.

Figure 2 Simple Stir casting setup

2.4. Modeling and Analysis of the Composite Disc Brakes

The design of the composite disc brake carries the following specifications Diameter =

357mm and Overall Thickness = 40mm.

Figure 3 Complete Disc Brake System Assembly



2.5. Analysis of the Composite Disc Brake Rotor

The basic types of analysis are of two types, they are,

1) Steady state analysis which determines all the loading conditions under steady state. In a

steady state loading conditions is a situation where the loading effects varying over a time

period of time can be ignored.

2) Transient Analysis which determines all the loading conditions over a period of time. [14-

17]

The finite elemental analysis method for the analysis of the aluminium cenosphere

composite disc brake is carried out in the following ways [18],

1. Thermal Analysis

2. Structural Analysis

3. Coupled thermal-structural Analysis

4. Contact analysis

2.6. Material Properties

Table 1 Material properties

Properties Al10ceno

Pad

Density (kg/m3) 2124 1400

Young’s Modulus (GPa) 70 1

Ultimate Tensile Strength

(MPa)

125 -

Poisson ratio - 0.25

Thermal Conductivity

(W/m. k)

159.3 5

Coefficient of Thermal

Expansion (C-1)

12.1×10-6

10×10-6

Notes: Al10ceno - Since, Aluminium with 10% cenosphere has enhanced mechanical and tribological

properties when compared with other aluminium-cenosphere composites. So, it is chosen as the

perfect material for the current application.[19-23]

2.7. Boundary Conditions and Loading

Table 2 Thermal Load Input Conditions

Object Name Convection Heat Flux

Scope

Scoping Method Geometry Selection

Geometry 235 faces 2 faces

Definition

Type Convection Heat flux

Film Coefficient 271.22 W/m²·°C

(ramped) -

Ambient Temperature 22. °C (ramped) -

Magnitude - 3.7691e+005 W/m²




Table 3 Structural Load Input Conditions

Object Name Rotational

Speed

Pressure Fixed Support Remote

Displacement

Scope

Geometry 2 faces (PAD) 24 Faces

Definition

Type Rotational

Speed

Pressure Fixed Support Remote

Displacement

Define By Component Normal To -

Magnitude 3.44e+006 Pa -

X Component 3000 RPM - 0. m

Y Component 0 - 0. m

Z Component 0 - 0. m

Rotation X - - - Free

Rotation Y - - - 0. °

Rotation Z - - - 0. °

Table 4 Structural Contact Input Conditions

Object Name Frictional - Multiple to

Part 3

Scope

Contact 2 Bodies

Target 1 Body

Contact Bodies Multiple

Target Bodies Part 3 (Rotor)

Definition

Type Frictional

Coefficient of Friction 0.35

Figure 4 Rotational Velocity with respect to Time



3. RESULTS AND DISCUSSION

3.1. Steady State Thermal Conditions

The temperature distribution and Heat flux distribution of the steady state thermal analysis is

shown in the following Fig.5.;

Figure 5 Temperature Distribution and Total Heat Flux over the Disc Brake Rotor

3.2. Steady State Structural Conditions

The total deformation of the steady state structural analysis is shown in the following Fig.6

Figure 6 Total Deformation of the Disc Brake Rotor

3.3. Steady State Contact Conditions

The penetration and frictional stress of the steady state contact analysis is shown in the

following

3.4. Steady State Coupled Thermal-Structural Conditions

The total deformation of the steady state coupled thermal-structural analysis are shown in the

following Fig.7




Figure 7 Total Deformation of the Disc Brake Rotor

3.5. Transient State Thermal Conditions

The temperature and Heat flux distribution of the transient state thermal analysis is shown in

the following Fig.8.,

Figure 8 Temperature Distribution and Total Heat Flux (Transient) over the Disc Brake Rotor

3.6. Transient State Structural Analysis

The total deformation of the transient state structural analysis is shown in the following

Fig.9.,

Figure 9 Total Deformation (Transient) of the Disc Brake Rotor



3.7. Transient State Contact Conditions

The penetration and frictional stress of the transient state contact analysis is shown in the

following Fig.10.,

Figure 10 Penetration & Frictional Stress (Transient) of the Disc Brake Rotor

3.8. Transient State Coupled Thermal-Structural Conditions

The total deformation of the transient state coupled thermal-structural analysis is shown in the

following Fig.11.,

Figure 11 Total Deformation (Transient) of the Disc Brake Rotor

The results are analyzed and found some enhancement in the performance of the

aluminium-cenosphere composite material in the disc brake rotor. The composite material

used in the disc brakes is light weight and has better wear resistance than the monolithic

element because of the presence of cenospheres. Also, the cenospheres which are present in

10% of volume in aluminium is having better thermal resistance properties and they will resist

the heat penetration deep inside the material. The heat generated due to friction can be

dissipated through disc brake fins at the center, this makes the life cycle of the disc brake

efficient.

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FABRICATION AND COMPUTATIONAL ANALYSIS … of aluminium composites in the current years. ... Fly ash particle used in current work is ... application and the demand for lightweight