Project Work(Phase-II) Review-I Name: K.MAHESH KUMAR Reg No:200821427 Project Guide: Dr.K.Malar Mohan.Ph.D.

, Assistant Professor AU-FRG Institute for CAD/CAM Anna University Chennai-25

Crack changes the dynamic behaviour of the structure and by examining this change, crack size and position can be identified

Extracting modal parameters like mode shape, natural frequency and damping to detect crack in brake disc.

Selection of disc brake that will be used or tested in this project Modeling the disc brake in Pro-E Performing modal analysis in ANSYS v13.0 Performing Experimental Modal Analysis using Shaker Comparison between Simulation and Experimental

The basic idea is that the modal parameters are, by definition, functions of the physical properties of components such as mass, stiffness or modulus of elasticity and hence of mechanical properties. This concept was used mainly in the application of modal testing

Physically, a crack of length 30mm to a depth of 10mm in the disc brake is made by EDM of wire size 0.25mm In FEA, the crack width of 0.35mm of the same length and depth is made using ANSYS. Element Used for meshing is Shell65 Analysis Type: Modal Mode Extraction Algorithm :Block Lanczos

Material Selected : Density : Modulus Of Elasticity : Poissons Ratio :

Grey Cast Iron 6900 kg/m3 110 Gpa 0.211

Mode No

Nat Freq (Hz)

0 0 1.12E-03

Mode No

Nat Freq (Hz)

58.353 91.72 92.414

Mode No

Nat Freq (Hz)

169.62 205.85 220.23

Mode No

Nat Freq (Hz)

323.87 326.27 346.83

Mode No

Nat Freq (Hz)

453.29 456.84 459.27

1 2 3

11 12 13

21 22 23

31 32 33

41 42 43

4
5 6 7 8 9 10

1.39E-02
1.84E-02 3.34E-02 21.823 22.037 48.391 58.23

14
15 16 17 18 19 20

100.68
105.89 107.54 109.65 156.22 166.22 169.12

24
25 26 27 28 29 30

240.32
251.35 252.13 262.55 265.48 289.67 294.73

34
35 36 37 38 39 40

349.75
382.33 406.91 418.22 435.66 448.08 453.28

44
45 46 47 48 49 50

463.52
466.87 477.23 483.37 484.56 491.13 493.36

Uncracked Disc
Mode No Nat.Freq (Hz)

Cracked Disc
Mode No Nat.Freq(Hz) % decrease

30

322.011

30

295.218

8.32

50

588.98

50

499.822

15.14

J.He , and Z.F.Fu, Modal Analysis, Oxford, ButterworthHeinemann,2001. M.Z.Hassan, Brake disc performance: FEA,Msc.Thesis,Coventry University,Coventry,UK,2004. DJ Ewins: Modal Testing: Theory, Practice and Application, Research Studies Press Ltd., New York(1984) A.L.Gyenkenyesi,J.T.Sawichki and G.Y.Baaklini, Vibration Based Crack Detection in a Rotating Disk Part I- Analytical Study,NASA,2003. Haileleoul Sahle, Cracked Detection in Rotating Disc, MSc.Thesis, Addis Ababa University,2004. J.C.Bae and J.A.Wickert 2000 Journal of Sound and Vibration 235(1),117-132.Free Vibration of Coupled Disk-Hat Structures.