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Application of SiC and Graphite reinforced Aluminium Metal Matrix Composite in Braking Systems and its Validation Through Finite Element Analysis

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Abstract

Smooth and efficient braking has always been a crucial factor to influence the efficiency of an automobile. This factor has prompted several researchers to indulge in the never-ending chase for a constant development and innovation in the domain of braking systems. Recent progress in this field is evident from the implementation of the new disc brake systems replacing the conventionally used drum type brakes. However, the conventionally existing disc braking systems are continuously exposed to the significant thermal and mechanical stresses that causes structural deformation, overheating, thermal cracking, and squeals of the rotor, which pose a threat to the lifetime and future performance of the rotor pads. Generally, in industrial automobiles, grey cast iron is used as rotor material since it exhibits positive results to thermal and mechanical loads, however investigations demonstrated that superior results can be obtained using other materials as well. Hence in the present study, an attempt to use SiC/Graphite reinforced Aluminium alloy (LM6) as an efficient alternative has been made. Consequently, the performance of the fabricated material was initially estimated through several thermal and mechanical investigations of tensile tests, compression tests, thermal conductivity, thermo-mechanical analysis and differential scanning calorimetry. Moreover, with an intention to validate the experimental observations, and to predict the real-life performance, finite element analysis on disc brake rotor of Maruti Alto 800 was conducted. The 3D model of the rotor was designed on Catia V5R20 using actual measurements of the disc brake prototype. This 3D model and measured parameters were used as an input feed for the accurate simulation of modal, structural and thermal behaviour in ANSYS 18.1 FEA software. The results of the experimentations were observed to be in good agreement with the simulation results, indicating the accuracy of the experimental predictions.

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Acknowledgement

The authors would like to acknowledge Dr. Sudhir Chandra Sur Institute of Technology and Sports Complex for allowing work on the research and visit multiple colleges and universities for experimental and research purposes. The authors would also be thankful to Surface Engineering and Tribology Lab, CSIR-CMERI, Durgapur, India for allowing us inside his laboratory for the research experiment and letting us work on NETZSCH LFA-467 hyper flash (Selb, Germany), India.

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This research received no specific grant from any funding agency in the public, commercial, or not-for-profit sectors.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Dr. Sudhir Chandra Sur Institute of Technology and Sports Complex, Kolkata, India

    Arpita Chatterjee & Subhodeep Paul

  2. Department of Mechanical Engineering, National Institute of Technology, Imphal, Manipur, India

    Arpita Chatterjee & Goutam Sutradhar

  3. Department of Mechanical Engineering, Budge Budge Institute of Technology, Kolkata, India

    Pallab Roy

  4. Department of Metallurgy and Materials Engineering, Indian Institute of Engineering Science and Technology, Shibpur, Howrah, India

    Soumyadeep Sen & Manojit Ghosh

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  1. Arpita Chatterjee
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Chatterjee, A., Sen, S., Paul, S. et al. Application of SiC and Graphite reinforced Aluminium Metal Matrix Composite in Braking Systems and its Validation Through Finite Element Analysis. J. Inst. Eng. India Ser. D 104, 449–464 (2023). https://doi.org/10.1007/s40033-022-00442-x

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