Abstract:

One of the most important parts in automotive, aviation, and rail systems are brake discs. Disc brake systems, which were first introduced in the 1950s, have undergone much advancement to reach the current technology, but they are still systems that continue to be developed. In frictional braking systems, heat is generated. When this temperature exceeds a certain level, the friction coefficient decreases due to the properties of the frictional element, which is the brake pads. This situation increases the stopping distance of the vehicle in long braking situations (such as downhill for heavy-tonnage vehicles or challenging tracks for sports cars) and reduces the service life of the braking and wheel group equipment. Therefore, the cooling structure of the brakes is crucial for both driving safety and vehicle security. This study aims to reduce the heating of the brake disc during prolonged use in sports cars and heavy-tonnage vehicles, improve the brake performance, achieve shorter stopping distances, and ensure driving and vehicle safety. In this study, a cage structure modeling approach was applied to enhance the cooling performance and reduce the weight of a sample brake disc designed for use in a sports car compared to traditional manufacturing methods. All design approaches were considered in light of the innovative possibilities and capabilities offered by additive manufacturing technologies. As a result of iterations, a model was obtained that would be manufactured using the selective laser melting method, resulting in a 20% lighter mass and 35% lower Von-Mises stresses. For the standard and cage structure discs subjected to equal heat loading, the standard disc surface had a temperature of 440 °C, while the optimized design resulted in a temperature of 213 °C.

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