Abstract
A brake disc decelerates the vehicle through friction with the brake pads. When the brake system is overheated, brake fade can occur, in which the friction coefficient drops significantly. Additionally, an over-heated brake system may cause vapor lock, in which the brake hydraulic fluid is vaporized. These phenomena can lead to the loss of braking power and cause a fatal accident. Therefore, brake systems must have stable braking and heat dissipation performance. Having through-holes and slits on the friction surface of the rotor has been adopted to improve the heat dissipation performance, but the holes become stress points and potentially cause cracks. Therefore, brake systems should be designed to have structural stability as well as good heat dissipation. In this study, finite element (FE) modeling was developed to analyze the structural stability and heat dissipation performance of a brake system, and structural and thermal simulations were performed in ANSYS, a CAE software package. In addition, to minimize concentrated stress and temperature, optimal design of the shape and pattern of holes and slits was carried out using PIAnO, an integrated optimal design software package. The first step of design optimization was performed while considering the shape and pattern of the disc holes and slits as design factors. Among the design factors, those with the largest effects on the objective functions were found and set as new design factors to perform the second step. The designs were compared to existing discs. Through the optimization presented in this paper, it is expected that the performance of the braking system will improve and the life of the brake parts will be increased.
Highlights
IntroductionA disc brake is a braking system composed of a brake rotor, brake pads, and calipers
A disc brake is a braking system composed of a brake rotor, brake pads, and calipers.The brake rotor rotates with the wheel, and the brake pads are mounted on the brake calipers, which clamp the rotor to stop or slow the wheel
The degree of stress concentration differed depending on the location of the hole, concentrated stress appeared around the holes in the rotor, and the highest stress occurred in parts of the ventilation blades
Summary
A disc brake is a braking system composed of a brake rotor, brake pads, and calipers. The brake pads generate frictional heat by converting kinetic energy into thermal energy to reduce the kinetic energy of the vehicle. There is a trade-off relationship between the cooling performance and structural stability of a brake disc [1,2]. Ventilated discs are generally used to improve the heat dissipation performance. A ventilated disc has the form of a general disc with added ventilation blades that help dissipate heat. The temperature rise can be suppressed even at medium and low speeds with small centrifugal force through holes on the outer surface, and the cooling performance caspnebeedms waxitimh iszmedalbl yceintreirfluogcaklinfogrwceitthhrthoeugvhenhtoillaetsioonnbtlhaedeosu. The hole shapes and the arrangement patterns are the elements which have the largest effects on the objective functions and were determined as design factors to formulate the optimal design.
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