MEE20002 Project: Electric Scooter Design, FEA & Sustainability Report

This project report details the design and analysis of an electric scooter, focusing on sustainability and finite element analysis (FEA). The design process incorporates sustainable principles to minimize environmental impact, including material selection and waste reduction. The report presents ANSYS results for thermal analysis of the brake disc and caliper, evaluating heat flux and temperature distribution to optimize performance and durability. The design incorporates components like a hub motor assembly and brake shoe assembly. This document is available on Desklib, a platform offering a wide range of solved assignments and study resources for students.

Sustainability and Finite element analysis

Table of Contents
1. Sustainable design...................................................................................................................2
1.1 Findings of the literature survey.......................................................................................2
1.1.1 Hub Motor Assembly................................................................................................2
1.1.2 Brake shoe assembly..................................................................................................3
2. ANSYS results.........................................................................................................................4
2.1 DISC Thermal analysis.....................................................................................................4
2.2 Caliper...............................................................................................................................6
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1. Sustainable design
1.1 Findings of the literature survey
Sustainable design creates us sensation similar to we are providing anything for the world or
upcoming age group. It is the philosophy of making physical objects, the environment, and
facilities to observe with the values of environmental sustainability. Green design is a method to
structure that reduces the damaging effects on human strength and the atmosphere. Sustainable
design is the purpose to minimize or remove bad ecological influences through caring plans. This
idea can function in every area of plans. When we go into sustainable design, we should not
believe to identify further we prepare about the desires of the future. Creed is one of the dares
against it. Imagine we discover a knowledge that improves carbon footmark. It decreases the
occurrence of cancer and keeps water distributions. We should identify that global warming is
the task after the 20th century (Bejan and Peder Zane, 2012). When that knowledge develops,
carbon footmark slightly linked with further activities which are costless. The knowledge
controls a major donor to sick and water ecology destruction. So we should be more confident to
develop the correct choice due to the problem of the carbon cost accountant. In these choices,
there must be a feature of the consisted group (Belhocine and Bouchetara, 2012). They can’t be
assumed by the only one designer’s task. We should identify that sustainability had a central
market constituent. Sustainable designs are seen all over the world. That is from reconsidered
transport schemes to another age group energy schemes. Sustainable design can provide qualities
of products that vibrate with people. The design group has the genetic material to search and
carry supportable results which are desired by culture, we should evaluate this central principle
further regularly. The main aims are to minimize the consumption of non-renewable resources,
reduce waste, and implement healthy, productive surroundings.
Based on the above founded principles and concepts we developed the design and they are
shown in the below sections.
Manipulative factors for existence: Woe is the executive, Dean is the section head that must
reflect the opinions of the initial U.S flagrant officer that all of the significance is conceived had
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been previously discovered. To be repeatedly model categories had been rationalized by
leguminous lifetime systems that consider model had no logical things. It is acquired easily as a
material. Possibly the impressive law of model, mutuality attack as well as also the subcontract
executive tasks. So in this problem, we will search for presenting the resourceful procedures
invoked by the superficial production team. It is sacked by applied information that must guide
the formation of innovative gadgets. It harvests FSMs means Forehead Slapping Moments with
expletives of “it’s too easy, I just had to think about it”, and it is positive “it’s clean then again I
saw how I must create it more superior”. Definitely, best executives as well as the modelers had
labored as a group. It is due to the ecosphere wants only regenerated power devices. Then again
the deceptive cheap price of coal, the group needs to put more effort. The group wants to labor
cleverer, tougher, as well as extra productively to protect our globe individually. Then again
provide the cheap price of coal, the improvement capability for best resolution creation in the
model:
All modelers and manufacturers must be like a maintainable modeler. It must involve that model
had not shown only. It moreover fulfills purposes of the customer that had been supportable. It
illustrates that newer inducement surroundings must support give and take of items when
producing customer notices by dual production items collection models. The old model results
had not to be manufactured by their architecture as well as creating selections. They also depend
on the passage, supplying as well as the item’s life span.
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1.1.1 Hub Motor Assembly
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Bill of Materials
1.1.2 Brake shoe assembly
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2. ANSYS results
The analysis step is done through the three steps. They are preprocessing, find solution and result
generation.
The preprocess step also involved in several steps. They are Material selection, develop
geometry and mesh creation (Doi et al., 2010). The stainless steel disk material is selected for
this analysis process. The next step is a geometry development. There is no specific tool to
develop geometry. So develop a geometry through importing the mesh files or through the
external files. The third step is the mesh creation. Here we create the fine mesh. In the mesh, the
creation steps the geometry is divided into nodes and elements. The mesh with the material
properties are used to represents the structure stiffness. To achieve a successful mesh, the
fineness should be adjusted at least four times.
Next step is to find the solution. For that, we need to do the following steps. The first step is to
set the boundary conditions. The boundary condition sometimes called as support or load. The
boundary conditions are applied at the time of the 3D or the 2D simulation analysis. The
boundary conditions are set a constant in the tabular entries or sometimes is defined as functions.
There are two types of boundary conditions are present. They are imported boundary conditions
and remote boundary conditions. The next step is loading. The load is applied based on the
analysis. For the thermal analysis it uses the temperatures and convections also for the stress
analysis it uses the forces and pressures for the load. The load is applied to the rigid dynamics,
static structural, magnetostatic and transient structural analysis. (Efficient Shape and Material for
Performance Disc Brake by Coupled Structural & Thermal Analysis, 2016) The final step is the
solve equation step. To solve each equation presents in the analysis appropriate solver is used.
For that the mechanical pass the data to the solver. Then the solver solves the equation and
returns the results back to the mechanical.
The last step in the analysis process is a result generation. The analysis type defines the results.
So in that part, we can see the thermal results, electric results, magnetostatic result, and structural
result. We can view the results by clicking the result object in the tree (Flumerfelt, Halada and
Kahlen, 2012).
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2.1 DISC Thermal analysis
There are three functions are used in the disc thermal analysis such as reduce the speed, maintain
the speed and stop the vehicle. There are two types of discs such as ventilated disc and full disc.
The above figure shows the ventilated disc thermal analysis for the total heat flux. It is more
complex geometry. It is a three-dimensional figure. The maximum value is 3.5744e5 Max. the
minimum value is 10.539 Min. Heat is the major part in the brake disc. It is greater than ninety
percent (FURUYA, 2018). The heat flux is loading on the ventilated disc surface. The parameter
and dimension are used in the thermal analysis.
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The ventilated disc there are three elements are used for the meshing. It was developed in the
disc pad. The temperature differs significantly so the mesh is important. The thermo powered
grades are high. Three meshes are automatically tested using ANSYS workbench. The above
picture shows the steady state thermal directional heat flux. It is a three-dimensional picture. The
global coordinate system unit is W/m2. The x-axis represents the maximum value. The y-axis
represents the middle value is 37406 of the directional heat flux. The z-axis represents the
minimum value is -3.0641e5 Min (Ganesh and Abinaya, 2015).
The above picture shows the steady state thermal temperature. The unit is 0C. The brake disc
rotor modeling is finished with the Solidworks. The above picture is imported in Ansys. The
steady state thermal analysis is completed to find the minimum and maximum temperatures. The
minimum temperature value is 21.546 Min. The maximum temperature value is 60 Max. The x-
axis is the max value. The z-axis is the min value. The z-axis is the center value of the steady
state thermal analysis temperature. (Pei, Guo and Wei, 2013)
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2.2 Caliper
In this figure, the thermal analysis results of the calliper are shown. Calliper is the part that
accommodates the braking cylinder, brake pad etc. In the braking system, most of the failures are
noticed in this part. When the application of the brakes this system absorbs a huge amount of the
heat energy dissipated by the brake disc and brake pad. When compared to the brake disc this
element faces problems because of its lower heat dissipation area. Also, brake disc rotates with
the wheel. So it cooled by the air pass on it. In the case of calliper it not moving part, it is
attached with the fork (Sheldrick and Rahimifard, 2015). Here we conducted four different types
of analysis on the calliper. And the results are shown below.
The above figure shows the temperature distribution on the calliper. On the calliper the highest
temperature noticed is 60 oC. It is noticed on the walls of the calliper. This is because of the heat
energy transmitted from the disc. Here heat transfer occurs in all the three modes (conduction,
convection and radiation)
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The above image shows the heat flux on the calliper. The heat flux plot shows the heat transfer
from the one end of the part to another end of the part. Here the heat is transferred from the disc
to the calliper. From the figure that is clear heat flux mostly founded on the inner walls. It
clearly defines that the heat is transferred from the disc to calliper. That shows that the developed
design effectively dissipate the heat absorbed. It increases the life of the braking system. Also, it
improves braking efficiency. In the below section the directional heat flux, as well as a thermal
error on the system, are illustrated.
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