Lightweight design of a torque plate of Z-cam drum brake for heavy duty vehicles

Year 2019, , 42 - 50, 30.06.2019

İbrahim Can Güleryüz

https://doi.org/10.30939/ijastech..568059

Cited By: 4

Abstract

Reducing vehicle
weight without compromising performance becomes an area which is important to
improve fuel economy and reduce vehicle emissions. The possibility of reducing
unsprung mass in a vehicle has led to many investigations of weight
optimization studies of axle and wheel-end components. Therefore, structural
design of a torque plate, which is one of the main parts of a Z-cam drum brake
used in heavy-duty vehicles, is carried out by using topology optimization and
finite element analyses. Firstly, finite element analysis of the original
torque plate is conducted to determine critical stress levels and locations.
Secondly, topology optimization is carried out on the original torque plate for
specified loading conditions. Taking redundant volume and manufacturability
constraints into account a new torque plate design is composed. Finally, finite
element analysis is repeated to verify the final design. A significant decrease
in stress level is accompanied by considerable reduction in casting and machined
part masses by 11.9% and 12.2% respectively.

Keywords

Torque plate, topology optimization, finite element analysis, Z-cam drum brake, heavy duty vehicles

Thanks

The author(s) would like to acknowledge and thank Ege Fren Sanayii ve Ticaret A.S. for the supporting this research. Special thanks to Richard Thompson C.Eng. for contribution in recommendations that greatly improved the paper.

References

• Limpert, R. Brake design and safety, SAE, 1992.
• Guleryuz, I. C. Modelling, Analysis and Experimental Verification of Pneumatic Brake System. MSc Thesis, Izmir Katip Celebi University, TR, 2017.
• Day, A. J. Braking of road vehicles. Butterworth-Heinemann, 2014.
• Reif, K. Brakes, Brake control and driver assistance systems. Weisbaden, Germany, Springer Vieweg, 2014.
• Sayim, I. and Zhang, D. Optimization of the brake factor for an S-Cam foundation brake using RSM/Optimizacija zavornega faktorja pri bobnastih zavorah z S-odmikalom po metodi odzivne povrsine. Strojniski Vestnik-Journal of Mechanical Engineering, 2016; 62.9: 503-511.
• Hecht Basch, R., Fash, J., Hasson, R., et al. Initial dynamometer and laboratory evaluations of thermally sprayed aluminium brake disc. Barton D, Earl S, Brakes, 2000; 11-12.
• Sergent, N., Tirovic, M. and Voveris, J., Design optimization of an opposed piston brake caliper. Engineering Optimization, 2014; 46.11: 1520-1537.
• Mathur, A. and Kurna, S. Weight optimization of Axle Beam using Optistruct, In: Altair Technology Conference, India, 2015.
• Topac, M. M. and Atak, M. Optimal design of a rigid front axle beam for trucks, In: 1st International Mediterranean Science and Engineering Congress (IMSEC 2016), Çukurova University, Congress Center, Adana/Turkey, October 26-28 2016, paper no. 453.
• Topac, M. M., Kuralay, N. S. and Bahar, I. Mass and Stress Optimisation of a Multi-Purpose Vehicle Front Axle Differential Housing For Various Driving Conditions, Düzce Üniversitesi Bilim ve Teknoloji Dergisi, 2016; 4: 501-513.
• Topac, M. M., Bahar, E., Kaplan, A., et al. Design of a lower wishbone for a military vehicle independent front suspension using topology optimization. In IDEFIS 2017: 2nd International Defence Industry Symposium, 2017, pp.333-342.
• Yucel, U., Yilmaz, B., Guleryuz, I. C., et al. A back-plate weight optimization of a heavy-duty s-cam drum brake, In: International Mechanical Engineering and Technologies Conference Proceedings (MECHATECH'16), May 17-18 2016, Istanbul/Turkey, pp.218-235.
• Zhang, Y., Zhang, H., and Lu, C. Study on parameter optimization design of drum brake based on hybrid cellular multiobjective genetic algorithm. Mathematical Problems in Engineering, 2012; 734193.
• Ragothaman, G., Krishnan, R. A., Balamurugan, A., et al. Design and Analysis of S-Camshaft And Torque Plate, International Journal of Pure and Applied Mathematics, 2018; 119.12: 13515-13522.
• Kuralay, N. S. Motorlu Taşıtlar; Temel ve Tasarım Esasları, Yapı Elemanları, Izmir: TMMOB Makina Mühendisleri Odası, 2008.
• Johnsen, S. Structural topology optimization: basic theory, methods and applications. MSc Thesis, Institutt for produktutvikling og materialer, 2013.
• Navarrina, F., Muiños, I., Colominas, I., et al. Topology optimization of structures: a minimum weight approach with stress constraints. Advances in Engineering Software, 2005; 36.9: 599-606.
• Bakhtiary, N., Allinger, P., Friedrich, M., et al. A new approach for sizing, shape and topology optimization. In: SAE international congress and exposition, Detroit, Michigan, USA, February 26-29 1996, 745-761.
• Bendøse, M. P. and Sigmund, O. Topology Optimization: Theory, Methods and Applications. ISBN: 3-540-42992-1. 2003.