Eventos Anais de eventos
COBEM 2021
26th International Congress of Mechanical Engineering
Baja SAE vehicle brake disc design through a thermo-structural analysis using the finite element method
Submission Author:
Ludmila Martins de Araújo , PB , Brazil
Co-Authors:
Mateus Feitosa Camboim, Ludmila Martins de Araújo, Nathalya Rebeca Melo da Cunha, Rodolfo Vieira Sarmento
Presenter: Mateus Feitosa Camboim
doi://10.26678/ABCM.COBEM2021.COB2021-1720
Abstract
The present work aims to dimension the Baja SAE vehicle rear axle brake disc with renowned tools in the development of mechanical projects such as ANSYS INC support; to simulate brake disc working conditions in order to obtain the working temperature and the stresses induced by temperature and mechanical stresses through a thermo-structural analysis and, from the results, select the most suitable material for this application best performance. Over the years and with constant technological advancement, industry had to adapt to launching new products ever shorter interval. The demand for better, cheaper and more technological products has required companies to be qualified to meet and keep up with market change speed due also to rivalry. In contrast, technological advancement in the automotive field also helps industries evolution through engineering software emergence that made a new product development much faster and cheaper. Likewise, academic projects such as Formula SAE and Baja SAE have benefited from engineering tools power, since simulation software using finite element method dramatically reduces project definition time and prototyping costs, helping to improve academic engineering and, consequently, competitions level. It is in this context that this work seeks to detail the development of one of the pieces produced by the Baja SAE team at UFPB, seeking the optimization, reliability and continuous improvement of the prototypes, thus adding to the engineering achieved level in the academic environment. Thus, for the brake disc design, with ANSYS software aid, a thermal simulation was carried out in which the working conditions with different materials were replicated. After obtaining each material work temperature, only those that did not present a risk of fading, which could compromise their operation at high temperatures, were selected. Then, thermal analysis results were imported for a structural simulation, configuring a thermo-structural analysis, in which the stresses induced by the temperature were added to the stresses caused by the mechanical requirement. Thus, using as a selection criterion the DFMEA results and the density together with an optimized geometry, it was possible to reduce the mass by more than 50% compared to the previous model and achieve a safety coefficient greater than 1.7 for steels SAE 1020, SAE 1045, gray cast iron and for AISI 420 stainless steel, which guarantee reliability for the application. From this, a decision matrix was built considering the price and availability in the market for the choice of material.
Keywords
Brake Disc, Finite Element Method, Thermo-structural, steel, BAJA SAE, thermal simulation
