Browse Publications Technical Papers 2018-01-1897
2018-10-05

Physical and Virtual Simulation of Light Weight Brake Drum Design for Heavy Duty Commercial Vehicles Using Alternate Material Technologies 2018-01-1897

Brake drum in commercial vehicles is very important aggregate contributing towards major weight in brake system module. The main function of brake drum is to dissipate kinetic energy of vehicle into thermal energy, as a results in braking operation major load comes on brake drum. Hence this is very critical component for vehicle safety and stability. Objective of this paper is to increase the pay load, which is utmost important parameter for commercial vehicle end customers. To achieve the light weighing target, alternate materials such as Spheroidal graphite iron (SGI) and Forging Steel have been evaluated for development of brake drum. Many critical parameters in terms of reliability, safety and durability could be the cross section, thickness of hub, wheel loading, heat generation on drum, manufacturing and assembly process are taken into consideration. The sensitivity of these parameters is studied for optimum design, could be chosen complying each other's values. Digital thermal performance evaluated in house, fine-tuned and verified by correlating with test data available for existing cast iron design and then applied for new design with alternate materials. In two different designs around 10 Kgs weight saving has been achieved as compared to conventional grey cast iron brake drum. Considering the most demanding 10x2 haulage platform in current commercial market, customer satisfaction index has been improved by approx. 100 Kgs payload increment for fleet owners, which will result in end customer profitability.

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