Coupled Field-Based Design Optimization Brake Discs Rotor for Braking System

Abstract

Efficient thermal management and structural integrity are essential for ensuring the reliability and safety of automotive braking systems. Conventional grey cast iron brake disc rotors, while widely adopted, often suffer from limitations such as high thermal stresses, localized deformation, and insufficient heat dissipation under severe braking conditions. These shortcomings can lead to reduced braking efficiency, premature wear, and compromised durability. The current study examines the thermo-mechanical performance of a grey cast iron brake disc rotor through geometry-based optimization using finite element modeling. The objective is to improve heat transfer capability and the mechanical strength under transient braking load without changing the composition of the material used. A comparative analysis is conducted between the optimized model and three other benchmark models under various speeds from 800 rpm to 2000 rpm. It was found that the optimized rotor is able to reduce its maximum temperature by up to 22.5% with an improvement greater than 30% at low rotational speeds. Moreover, it has reduced Von Mises stress of about 18–25% and total deformation by 15–20% in comparison with benchmark models. This enhanced behavior can be attributed to better placement of slots and holes, leading to better convective heat transfer and minimizing temperature gradient. In addition, a more uniform heat flux distribution is observed, reducing localized hotspots and stress concentrations. This research proves the fact that there is enhanced braking efficiency and thermal stability through geometric optimization of the design, and can be used in real-world vehicle design applications.