Designing and Development of Braking System of Pulsar Bike by Using Stir Die Casted Disc of Al Metal Matrix Composite Having Better Co Efficient of Friction Wear and Thermal Properties

Abstract

Metal matrix composite offers outstanding properties for better performance of disc brakes. In the present study, the composite of AlTiCr master alloy was prepared by stir die casting method. The developed material was reinforced with (0 10 wt%) silicon carbide (SiC) and boron carbide (B4C). The effects of SiC reinforcement from 0 to 10 wt% on mechanical, microstructure and surface morphological properties of Al MMC was investigated and compared with B4C reinforcement. Physical properties like density and micro Vickers hardness number show an increasing trend with an increase in the percentage of SiC and B4C reinforcement. Mechanical properties viz. UTS, yield strength and percentage of elongation are improved with increasing the fraction of reinforcement. The surface morphology and phase were identified from scanning electron microscopy (SEM) and X-ray diffraction analysis and the oxidized product formed during the casting was investigated by Fourier transformation infrared spectroscopy. Micro-structural characterization by SEM depicted that the particles tend to be more agglomerated more and more with the percentage of the reinforcement. The Atomic force microscopy (AFM) results reveal that the surface roughness value shows a decreasing trend with SiC reinforcement while roughness increases with increase the percentage of B4C. newlineTo improve disc brake cooling performance we propose a new design in ventilated brake disc in the present work. Results of Thermal stress analysis of a aerofoil shaped ventilated cast iron disc have been compared with new proposed alloy disc with hexagonal shaped cut section and results has been encouraging. Both steady-state and transient simulations are performed using ANSYS CFX 14.5 based on the finite volume method and the time marching algorithm. The wear rate, coefficient of friction and contact pressure are derived from experimental measurements and applied to the computational designed model of the rotor. Both brake discs exhibit a similar temperature during initial period, while