Imperial Journal of Interdisciplinary Research (IJIR) Vol-2, Issue-6, 2016 ISSN: 2454-1362, http://www.onlinejournal.in Imperial Journal of Interdisciplinary Research (IJIR) Page 1195 Manufacturing of Disc Brake Rotor Using Aluminium Metal Matrix Composite (AMMC) reinforced with Silicon Carbide Parth S. Joshi, Kiran C. Hegade, Apoorv S. Kulkarni & Omkar V. Karale B. E. Students, Department of Mechanical Engineering, Trinity College of Engineering and Research, Pune, India Abstract: This paper deals with the manufacturing of disc brake rotor using AMMC. AMMC is the combination of aluminium and silicon carbide along with small quantity of other material like magnesium, aluminium oxide, graphite which are added in precise quantity to enhance the chemical, mechanical and thermal strength of material. The whole process is carried out in controlled environment. Gravity die casting is the suitable process used for the purpose. Pre-processing of additives are carried out precisely. Stir casting is one of the economical and extensively used methods to enhance attractive properties of AMC’s. This paper presents an overview of stir casing process, process parameter and preparation of AMC using aluminium alloy as matrix phase and alumina (Al2O3) as reinforcement Keywords: Aluminium Matrix Composite, reinforcement, stir casting. 1.Introduction Aluminium alloys are used in advanced applications because of high strength, low density, durability, machinability, availability and cost is very attractive compared to competing materials. The aluminum metal matrix composite materials is the combination of two or more constituents in which one is matrix and other is filler materials (reinforcements). Aluminum metal matrix may be laminated, fibers or particulates composites. Generally, grey cast iron is used to manufacture brake disc rotor, but AMMC is selected considering crucial advantages of the AMMC over cast iron material. Disc brake used for decelerating or stopping the automobile or to maintain a constant velocity or to park the vehicle. This specification dictates the correct range of hardness, chemical composition, tensile strength and other properties necessary for the intended use. Some racing cars and airplanes use brakes with carbon fiber discs and carbon fiber pads to reduce weight. In preparing metal matrix composites by stir casting method some of the factors that need considerable attention are as follows: To achieve uniform distribution of the reinforcement material To achieve wettability between the two main substances To minimize porosity in the cast metal matrix composite 1.1 Brake Disc Rotor The Disc Brake discs are commonly manufactured out of grey cast iron. The SAE maintains a specification for the manufacture of grey cast iron for various applications. For Normal car and light truck applications the SAE specification is J431 G3000 (superseded to G10). This specification dictates the correct range of hardness, chemical composition, tensile strength and other properties necessary for the intended use. Some racing cars and airplanes use brakes with carbon fiber discs and carbon fiber pads to reduce weight. Wear rates tend to be high and braking may be poor until the brake is hot. It is investigated that the temperature distribution, the thermal deformation and the thermal stress of automotive discs have quiet close relations with car safety; therefore, much research in this field has been performed. 1.2 Aluminium Metal Matrix Composite (AMMC) The term “composite” broadly refers to a material system which is composed of a discrete constituent distributed in continuous phase, and which derives its distinguishing characteristics from the properties of
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Imperial Journal of Interdisciplinary Research (IJIR)
Vol-2, Issue-6, 2016
ISSN: 2454-1362, http://www.onlinejournal.in
Imperial Journal of Interdisciplinary Research (IJIR) Page 1195
Manufacturing of Disc Brake Rotor Using
Aluminium Metal Matrix Composite
(AMMC) reinforced with Silicon Carbide
Parth S. Joshi, Kiran C. Hegade, Apoorv S. Kulkarni &
Omkar V. Karale B. E. Students, Department of Mechanical Engineering, Trinity College of Engineering and
Research, Pune, India
Abstract: This paper deals with the manufacturing of
disc brake rotor using AMMC. AMMC is the
combination of aluminium and silicon carbide along
with small quantity of other material like magnesium,
aluminium oxide, graphite which are added in precise
quantity to enhance the chemical, mechanical and
thermal strength of material. The whole process is
carried out in controlled environment. Gravity die
casting is the suitable process used for the purpose.
Pre-processing of additives are carried out precisely. Stir casting is one of the economical and extensively
used methods to enhance attractive properties of
AMC’s. This paper presents an overview of stir casing
process, process parameter and preparation of AMC
using aluminium alloy as matrix phase and alumina
(Al2O3) as reinforcement
Keywords: Aluminium Matrix Composite,
reinforcement, stir casting.
1.Introduction
Aluminium alloys are used in advanced applications
because of high strength, low density, durability,
machinability, availability and cost is very attractive
compared to competing materials. The aluminum metal
matrix composite materials is the combination of two
or more constituents in which one is matrix and other is
filler materials (reinforcements). Aluminum metal
matrix may be laminated, fibers or particulates
composites. Generally, grey cast iron is used to
manufacture brake disc rotor, but AMMC is selected
considering crucial advantages of the AMMC over cast
iron material. Disc brake used for decelerating or
stopping the automobile or to maintain a constant
velocity or to park the vehicle. This specification
dictates the correct range of hardness, chemical
composition, tensile strength and other properties
necessary for the intended use. Some racing cars and
airplanes use brakes with carbon fiber discs and carbon
fiber pads to reduce weight. In preparing metal matrix
composites by stir casting method some of the factors
that need considerable attention are as follows:
To achieve uniform distribution of the
reinforcement material
To achieve wettability between the two main
substances
To minimize porosity in the cast metal matrix
composite
1.1 Brake Disc Rotor
The Disc Brake discs are commonly manufactured
out of grey cast iron. The SAE maintains a
specification for the manufacture of grey cast iron for
various applications. For Normal car and light truck
applications the SAE specification is J431 G3000
(superseded to G10). This specification dictates the
correct range of hardness, chemical composition,
tensile strength and other properties necessary for the
intended use. Some racing cars and airplanes use
brakes with carbon fiber discs and carbon fiber pads to
reduce weight. Wear rates tend to be high and braking
may be poor until the brake is hot. It is investigated
that the temperature distribution, the thermal
deformation and the thermal stress of automotive discs
have quiet close relations with car safety; therefore,
much research in this field has been performed.
1.2 Aluminium Metal Matrix Composite
(AMMC)
The term “composite” broadly refers to a material
system which is composed of a discrete constituent
distributed in continuous phase, and which derives its
distinguishing characteristics from the properties of