SIKUMBANG, RAMA WIDJAYA (2026) MODELING DAN SIMULASI PERPINDAHAN PANAS PADA REM CAKRAM MOBIL MENGGUNAKAN SOFWARE FINITE ELEMENT ANALYSIS. S2 thesis, Universitas Mercu Buana Jakarta.
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Abstract
The disc brake system generates heat due to friction which may lead to overheating, non-uniform heat flux distribution, and thermal stress that can trigger cracks and deformation. This study aims to analyze the thermal and thermo-mechanical characteristics of disc brakes using three materials: Aluminium Alloy, Grey Cast Iron, and Stainless steel with three design models: (a) standard ventilated, (b) cross drilled, and (c) cross drilled–ventilated. The method employed ANSYS 2021 R2 simulations validated by manual calculations of transient thermal, steady-state thermal, and equivalent von-Mises stress. Results show that all materials reached peak temperatures close to 220°C, validated by manual calculation of ±219.9°C, indicating potential overheating if heat dissipation is not optimal. Total heat flux analysis revealed that model (c) provided the best heat release with the lowest steady-state temperature: Grey Cast Iron 75–90°C, Aluminium alloy ±75°C, and Stainless steel 60.16°C. Aluminium alloy on model (c) showed the most effective thermal performance despite high maximum heat flux (3.9077×10⁶ W/m²) due to the most uniform distribution. Von-Mises stress analysis indicated that geometry strongly affected mechanical safety; for Grey Cast Iron model (a) was safest at 220.05 MPa, for Aluminium alloy model (b) was best at 327.08 MPa, while Stainless steel exhibited very high stress (>1000 MPa) on all models indicating high risk of plastic deformation. It is concluded that model (c) is optimal for heat dissipation, whereas the safest mechanical combinations are Aluminium Alloy–model (b) and Grey Cast Iron–model (a). Kata kunci: Disc Brake, Thermal Analysis, Overheating, Aluminum Alloy, ANSYS Simulation Sistem pengereman cakram menghasilkan panas akibat gesekan yang berpotensi menyebabkan overheating, distribusi heat flux tidak merata, serta tegangan termal yang dapat memicu retak dan deformasi. Penelitian ini bertujuan menganalisis karakteristik termal dan termomekanik cakram rem menggunakan tiga material, yaitu Aluminium Alloy, Grey Cast Iron, dan Stainless steel pada tiga model desain: (a) ventilasi standar, (b) cross drilled, dan (c) cross drilled– ventilated. Metode penelitian menggunakan simulasi ANSYS 2021 R2 yang divalidasi melalui perhitungan manual transient thermal, steady-state thermal, dan equivalent von-Mises stress. Hasil menunjukkan ketiga material mencapai suhu puncak mendekati 220°C dan tervalidasi manual ±219,9°C, mengindikasikan potensi overheating apabila pelepasan panas tidak optimal. Analisis total heat flux menunjukkan model (c) memiliki pelepasan panas paling baik dengan suhu steady-state terendah: Grey Cast Iron 75–90°C, Aluminium alloy ±75°C, dan Stainless steel 60,16°C. Aluminium alloy pada model (c) memberikan performa termal paling efektif meskipun heat flux maksimum tinggi (3,9077×10⁶ W/m²) karena distribusi paling merata. Analisis equivalent vonMises stress menunjukkan desain sangat memengaruhi keamanan mekanik; pada Grey Cast Iron model (a) paling aman dengan 220,05 MPa, pada Aluminium alloy model (b) terbaik dengan 327,08 MPa, sedangkan Stainless steel menunjukkan tegangan sangat tinggi (>1000 MPa) pada seluruh model sehingga paling berisiko deformasi plastis. Dengan demikian, bahwa model (c) merupakan desain terbaik untuk optimasi pelepasan panas, sementara dari sisi tegangan kombinasi paling aman adalah Aluminium Alloy–model (b) dan Grey Cast Iron–model (a), menegaskan bahwa keberhasilan sistem pengereman ditentukan oleh sinergi material dan desain geometris. Kata kunci: Rem Cakram, Analisis Termal, Overheating, Aluminium Alloy, Simulasi ANSYS
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