Topology Optimization of Disc Brake

Heat generation and friction have long been a problem in the automotive industry. The braking system is one application where these come together and benefit the vehicle’s safety. Disc brakes must be able to provide sufficient friction force to stop the vehicle. To provide adequate braking force, a significant amount of heat is generated, which must be rapidly dissipated from the disc rotor or brake pad. Since the disc rotor is a rotating mass, it must be optimized because such masses have higher inertia and reduce vehicle efficiency. As a result, reducing the rotating masses will improve the overall performance of the vehicle and make it more cost-effective to operate. Topology optimization was carried out while keeping the size criteria constant and focusing solely on weight reduction as a major parameter. The obtained topology optimization geometries were further analysed and compared to the original under the same parameters, and it was discovered that the induced stresses and thermal limits were maintained with negligible changes. The optimized geometries ranged from 1.21 to 9.76% mass reduction for the five models created, for an average mass reduction of 6.23%.