Chapter 3 Model

3.1 mathematical modelling of the specimen

There are several theoretical models available for calculating the material composition of FGM
and defining a material property of an FGM material throughout. Theoretical models are power
law, exponential law, Mori-tanaka law, etc. The component is divided into several layers of very
thin uniform thickness and assumed that each layer will have homogeneous properties. The
exponenetial law and the power law give the best outcomes in terms of definig material property.

 Exponential law- Material properties like density, E, H, coefficient of thermal expansion

is defined by exponential law.
P(z)= Pt exp(-1(l-2z/h))
Where, P(z) is mat property
Pt material on top plane
P(b) material on bottom plane
L= 0.5 ln(Pt/Pb)
Z= height at which material property is defined
H= total thickness
 Power law- Material properties like density, E, H, coefficient of thermal expansion is
defined by power law.
P(z)= (Pt-Pb)(z/h-0.5)N + Pb
Where, P(z) is mat property
Pt material on top plane
P(b) material on bottom plane
Z= height at which material property is defined
H= total thickness
N= Volume gradient.
3.2 Variation of Modulus of elasticity and Thermal conductivity.

Material properties vary continuously across the thickness so it is required to code a program that
can define material property at any instance across the thickeness. The MATLAB software is
used to program material properties according to power law. Code is defined in such a way that
the user has to input some basic parameters like thickness, no of divisions desired and for which
volume gradation material properties are required. It will divide the material into desired layers
and property of each layer will be assigned on the mid point of that layer

The following table shows the values of variation in Modulus of elasticity and thermal
conductivity across a specified thickness for different volume gradation.
3.3 Modelling of Brake liner in Workbench

The design and modelling of the brake liner was carried out by the help of layer by layer
approach and the different material specifications for each layer was defined in engineering
data for a volume gradation value of n=2. The boundary conditions were set and the
parameters were defined. One face was given a fixed support while the other was assumed to
be under uniform loading conditions. This model was created by a layer by layer approach;
hence the results obtained are ideal and tend to differ from practical application. The material
selected for simulation is an Aluminium-ceramic based FGM material with bottom layer of
aluminium. The modelling was carried out in ANSYS
The material properties for the bottom and top layer of the liner are sown in the table given
below
Details of the model are as follows

Fig

Fig

The force parameters are listed in the table below. Since the liner is subjected to shear force
as well as normal forces at the same time, force is applied simultaneously in x and z
directions as listed. The brake liner is an annular pad and total 2 pads are used in the
assembly. The coefficient of friction is taken as 0.35 and avg. Pressure on pad to be 2 MPa.
Torque= 1500 N/mm.
 Fig
The mesh details and the meshed drawing is shown below. The meshing is coarse and in an
adaptive function.

Fig
 Fig

Chapter 4
Results and analysis
After the modelling and setting of various parameters, a comparative study of FGM and Asbestos
brake liner was performed and certain results were analysed and conclusions were drawn.
Here are the results of the same. The first results shown belong to Aluminium-ceramic FGM and
in total, the von-Mises stress, equivalent shear stress and total deformation have been calculated.
The results shown in the images below are at an enhanced scale which was automatically set by
the ANSYS software.
o Results for Aluminium-Ceramic based FGM
o Total deformation

Fig

 Von-Mises stress

Fig
 Equivalent stress

Fig

 Results for asbestos material

o Total deformation

Fig
 Von-Mises stress

Fig
 Equivalent shear stress

fig