Design synthesis and structural optimization of a lightweight, monobloc cast iron brake disc with fingered hub

Abstract

The article focuses on generating a monoblock fingered hub (top hat) disc design, aiming at reducing disc mass but maintaining rotor thermal capacity, whilst also improving heat dissipation characteristics. The analyses and tests demonstrated that such a design is possible to achieve, with mass reduction of just over 9%. The activities included research into cast iron modelling which gave very important insight into its limits of mechanical performance under bending. Initial Finite Element analyses enabled considerable progress towards establishing a baseline design but only through Shape Optimization and Topology Optimization procedures the full potential of the design have been accomplished. Shape optimization facilitated reduction of maximum principal stress by 32%, considerably improving disc torsional strength with practically no mass increase. The safety factor in torsion achieved the value of 3.57. Topology Optimization provided further, though small mass reduction (1.5%) whilst maintaining low stress levels.

Experimental investigation of the cooling characteristics of a monobloc cast iron brake disc with fingered hub

“…The main problem in generating such a design for passenger cars is related to the structural integrity of the fingered hub. The authors have demonstrated that such design is possible to establish, as detailed in [1]. There are however limitations, a) the vehicle needs to be light and corresponding maximum braking torque relatively low and b) the top hat offset needs to be small, resulting in a relatively 'shallow' disc design.…”

“…The authors have demonstrated that such design is possible to establish, as detailed in Topouris and Tirovic. 1 There are however limitations: (a) the vehicle needs to be light and corresponding maximum braking torque relatively low and (b) the top hat offset needs to be small, resulting in a relatively ‘shallow’ disc design. The vehicle selected was Lotus Elise S2 which has such a disc design (identical for both axles).…”

“…Initially, the discs were tested when rotating in still air, then the experiments were conducted in parallel and angular cross flow in the Thermal Flow Rig, with further details given by Topouris. 18…”

Lightweight Design of Special Axle Hub Based on ANSYS Consider Different Working Conditions for Low Carbon

“…erefore, the lightweight design of the hub is being discussed by experts and scholars. A lightweight designed monobloc ngered hub is studied by Topouris and Tirovic [11], aiming at reducing disc mass but maintaining rotor thermal capacity. Combine the reverse modeling technique with the topological optimization method to derive lightweight wheel hubs based on the principles of mechanics by Xu et al [12].…”

Structural Optimization of Vented Brake Rotors with a Fully Parameterized Model

“…Roy and Bharatish [23] employed five geometric parameters of a ventilated brake disc to minimize the maximum total deformation and equivalent stress of the model using the ANSYS software and the response surface methodology and achieved approximately 10% reduction in both deformation and stress. Topouris and Tirovic [24] performed shape optimization to minimize the maximum principal stresses on finger structures of a cast-iron brake disc and then topology optimization to reduce the mass of the disc. Finite element analysis and optimization packages, Abaqus and OptiStruct, were used in their research.…”