Design development and optimization of disc brake using generative design on fusion 360

Abstract

Generative design is growing in prominence across various engineering fields owing to the increased sophistication and convenience it provides to the design engineers, researchers and students. This work involves applying generative design feature during the initial stages of brake design to come up with an ideal design for a brake disc that precisely meets only the required criteria thereby saving material, cost and time. Brake disc is a critical part of the braking system and is used to produce friction large enough to stop the vehicle. But they are heavy. Reducing the weight will increase life of brake parts and lower inertia since brake is an un-sprung mass. This research is carried out with an aim to reduce the mass of brake discs while maintaining stiffness enough to withstand the braking forces acting due to the calliper and also the resultant friction produced by it. The frictional force produced during the braking action is converted into heat energy. This heat energy increases the temperature of the brake disc. Extreme high temperatures can cause brake fading problems which will lead to the disc being non-functional. Ideally; excellent heat dissipation is required to so that the heat produced never exceeds the thermal storage capacity of the brake disc material. This is commonly done by increasing surface area and providing proper air ventilation channels. Drilled holes, slots are made in the disc to increase the flow of air which helps in reducing and maintaining temperature. The average weight of brake disc used in automobiles are normally more than 5kg. Our aim is to reduce the weight under 2kg using generative design. Therefore, the challenge is to meet the requirements of mechanical performance while trying to reduce mass of the brake disc. The new results are compared with the conventional designs already available. The research further helps realise the existing limitations of generative design technology and its scope for becoming the primary method for design optimization process.