OPTIMIZING BRAKE DISC STRUCTURE THROUGH HEAT DISSIPATION AND MASS REDUCTION USING OPTISLANG

Abstract

A disc brake system comprises a rotor and opposing brake pads that, when actuated, generate frictional force to convert kinetic energy into heat, thereby decelerating the vehicle. During this process, the kinetic energy of the vehicle’s motion is converted into thermal energy, with part of the heat absorbed by the brake disc and the remainder dissipated into the surrounding environment. The amount of heat the brake disc absorbs significantly impacts its long-term durability. Therefore, selecting a material with excellent heat dissipation, sufficient mechanical strength, and cost-effectiveness is crucial. This study aims to analyze the heat generated during braking and evaluate the thermal dissipation efficiency of different materials. Three material types are considered: gray cast iron, C45 steel, and aluminum. The brake disc model is designed and analyzed in SolidWorks and ANSYS to simulate thermal and structural performance. optiSLang is employed to optimize the brake disc design regarding mass and temperature distribution by utilizing the Design of Experiments (DoE) method and sensitivity analysis. Through a systematic evaluation of various design parameters, an optimized configuration has been identified that enhances braking temperature management while reducing total mass by 10.85%, from 5.13 kg to 4.58 kg, and thickness by 10.46%. The results indicate that C45 remains the most effective material for brake discs, owing to its superior heat dissipation properties and lower overall mass.