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Materials 2018, 11(7), 1211; https://doi.org/10.3390/ma11071211

Design, Development and FE Thermal Analysis of a Radially Grooved Brake Disc Developed through Direct Metal Laser Sintering

Department of Mechanical Engineering, College of Engineering, King Khalid University, P.O. Box 394, Abha 61421, Saudi Arabia
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Received: 6 May 2018 / Revised: 9 July 2018 / Accepted: 10 July 2018 / Published: 13 July 2018
(This article belongs to the Special Issue Additive Manufacturing: Alloy Design and Process Innovations)
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Abstract

The present research work analyzed the effect of design modification with radial grooves on disc brake performance and its thermal behavior by using additive manufacturing based 3D printed material maraging steel. Temperature distribution across the disc surface was estimated with different boundary conditions such as rotor speed, braking pressure, and braking time. Design modification and number of radial grooves were decided based on existing dimensions. Radial grooves were incorporated on disc surface through Direct Metal Laser Sintering (DMLS) process to increase surface area for maximum heat dissipation and reduce the stresses induced during braking process. The radial grooves act as a cooling channels which provides an effective means of cooling the disc surface which is under severe condition of sudden fall and rise of temperatures during running conditions. ANSYS software is used for transient structural and thermal analysis to investigate the variations in temperatures profile across the disc with induced heat flux. FE based thermo-structural analysis was done to determine thermal strains induced in disc due to sudden temperature fluctuations. The maximum temperature and Von Mises stress in disc brake without grooves on disc surface were observed which can severely affect thermal fatigue and rupture brake disc surface. It was been observed by incorporating the radial grooves that the disc brake surface is thermally stable. Experimental results are in good agreement with FE thermal analysis. DMLS provides easy fabrication of disc brake with radial grooves and enhancement of disc brake performance at higher speeds and temperatures. Therefore, DMLS provides an effective means of implementing product development technology. View Full-Text
Keywords: design; disc brake; 3D metal printing; direct metal laser sintering; thermal stress analysis; radial grooves design; disc brake; 3D metal printing; direct metal laser sintering; thermal stress analysis; radial grooves
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).
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Sayeed Ahmed, G.M.; Algarni, S. Design, Development and FE Thermal Analysis of a Radially Grooved Brake Disc Developed through Direct Metal Laser Sintering. Materials 2018, 11, 1211.

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