Finite Element Analysis-Based Geometry Optimization of a Disk Brake

A disk brake is a mechanical component consisting of calipers to squeeze a pair of disk pad. These disk pads apply a pressure on the rotating disk and create friction. This friction generates the heat and slows the rotation of the shaft. Nowadays, disk brake is used in entire automobile vehicle and its performance was influenced by the geometric shape and heat dissipation. The main objective of present study is to optimize the design of disk brake. A CAD model of disk brake was designed in Catia and analyzed by Ansys. The disk was subjected to pressure and rotational velocity to perform the topology optimization under applied boundary condition. The simulation result shows that the mass was reduced to 10.7% and 10.5% for aluminum and carbon–carbon material made disk, respectively, under same loading condition. Furthermore, old and new optimized disk was analyzed for temperature loading. The result concludes that optimized frame can sustain the deformation and stress without failure.