Design of a lightweight automotive brake disc using finite element and Taguchi techniques

Abstract

Aluminium metal matrix composite brake discs offer significant weight advantages compared with the traditional cast iron rotor but have a much lower maximum operating temperature. In this study, a finite element model of an existing brake design is firstly used to predict the peak disc temperatures during two critical brake tests for both cast iron and an aluminium metal matrix composite alternative. A Taguchi analysis is then applied, enabling all the critical design and material factors of an aluminium metal matrix composite rotor to be considered collectively. Based on the results of this exercise, a parametric sensitivity study is carried out to define suitable design-material combinations for a prototype lightweight front brake disc to be used on small to medium passenger vehicles.