Thermal Stress and Thermal Expansion in a brake drum of heavy commercial truck

Brake system is one of crucial system in automobile. Poor performance or brake
failure will cause fatal accident especially for heavy transportation vehicle.
Excessive thermal stresses may canse undesirable effects on the material of brake
drum that eventually lead to the initiation of a crack. This dissertation investigates
the thermal stress and thermal expansion develops in a ~rake drum of heavy
commercial trnck due to temperature distribution in severe braking condition. The
analysis is done by simulate the temperature distribution and the thermal stress
distribution within the drum material nsing finite element approach in ANSYS
simulation program. Before the simulation work, dynamic of moving truck and
rotating drum are analyzed. Also, the energy conversion analysis is made to
determine amount of frictional heat flux created, which the values will be applied in
the simulation input for the temperature distribution. And the temperature
distribution result will be applied in the structural analysis field as the input for
thermal stress and expansion analysis. The simulation results give the highest
temperature of 255T at the middle of braking period which is 2.6 second. The
maximum thermal stress result is achieved 93 MPa at 1.32 second after braking
started and the maximum thermal expansion is achieved in radial expansion of 2.9
millimeter at 2.6 second of braking period. The evaluation of simulation results give
the information for prediction and contribute toward improving design, modeling
and analysis technique for integrity of thermo-mechanical system that subjected to
high temperature.