FABRICATION AND COMPUTATIONAL ANALYSIS … of aluminium composites in the current years. ... Fly ash...
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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
Assistant Professor, Department of Aeronautical Engineering,
Veltech Dr.RR & Dr.SR University, Chennai
G. Boopathy
Associate Professor, Department of Aeronautical Engineering,
Veltech Dr.RR & Dr.SR University, Chennai
G. Surendar
Assistant Professor, Department of Aeronautical Engineering,
Veltech Dr.RR & Dr.SR University, Chennai
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
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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
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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
Fabrication and Computational Analysis of Cenosphere Reinforced Aluminum Metal Matrix
Composite Disc Brakes
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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
R. Kousik Kumaar, G. Kannan, G. Boopathy and G. Surendar
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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
Fabrication and Computational Analysis of Cenosphere Reinforced Aluminum Metal Matrix
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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
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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
Fabrication and Computational Analysis of Cenosphere Reinforced Aluminum Metal Matrix
Composite Disc Brakes
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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
R. Kousik Kumaar, G. Kannan, G. Boopathy and G. Surendar
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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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