Research of a long-life brake disk manufactured using a forming process

The development of sustainable products and solutions is also becoming increasingly important in the automotive sector. For example, the new Euro 7 emissions standard is expected to regulate particulate emissions from brake systems to a maximum of 7 mg per kilometer for the first time from 2025 [1]. This requirement poses a new challenge for the development of wheel brakes.The Chair of Vehicle System Design is currently developing a new innovative brake disk with partners from industry and research. Unlike previous brake discs, this one is not made of gray cast iron, but of a corrosion-resistant steel alloy. The advantage of this is that a particularly cost-effective forming process can be used for production. In order to meet the Euro 7 standard, the friction surfaces are provided with a particularly hard wear protection coating. Furthermore, the geometric design of the brake disc is optimized for the use of steel as a material. To this end, extensive FEM simulations and tests were carried out using a dynamometer.The combination of corrosion-resistant steel and a wear protection layer makes it possible to produce a long-life brake disc. Manufacturing costs can be reduced by using a forming process for production. This enables the brake disc to be used in more cost-effective vehicle segments and still meet the future Euro 7 emissions standard.