DESIGN, OPTIMIZATION AND MANUFACRURING OF AUTOMOTIVE DISC BRAKES

Abstract

Automotive disc brakes are essential for vehicle safety, ensuring effective deceleration. This project aims to design and optimize disc brakes by integrating advanced materials, innovative design techniques, and cutting-edge optimization methods to enhance performance, durability, and safety. The study begins with a detailed analysis of disc brake requirements, including braking force, thermal management, wear resistance, and noise reduction. Finite element analysis (FEA) and other simulation tools are used to model brake performance under various conditions, such as high-speed braking and extreme temperatures. Material selection is key, focusing on lightweight, high-strength alloys and composites to improve braking efficiency while reducing vehicle weight. Optimization techniques are employed to refine the brake design. Multi-objective optimization algorithms aim to maximize efficiency, minimize wear, and improve heat dissipation, extending the lifespan of the brake components. The project also examines the influence of design variables like disc geometry, ventilation patterns, and friction material properties on overall performance. Software testing validates the optimized design through rigorous assessments of thermal cycling, friction performance, and durability. The results are compared with simulation data to ensure the design's accuracy and reliability. This iterative process of design, simulation, and testing results in a disc brake system that offers improved performance, reduced weight, and enhanced safety features. The project provides valuable insights into the design and optimization of disc brakes, contributing to the development of more efficient, reliable, and advanced braking systems for future automotive applications.