Design optimization for material reduction in motorcycle brake discs
Email:
hungtkm@utc.edu.vn
Từ khóa:
Brake disc; Design optimization; CAE; Finite Element Method (FEM); HyperMesh; Topology optimization; Modal analysis
Tóm tắt
Brake discs are essential components in motorcycle braking systems, where structural strength and thermal stability significantly affect vehicle safety and performance. However, conventional brake disc designs often encounter trade-offs between weight reduction and mechanical durability. This study aims to analyze and optimize the design of a motorcycle brake disc to reduce weight and stress while maintaining structural integrity and performance. A standard disc model from the HONDA LEAD (SCR) was reconstructed and analyzed using Altair HyperMesh, integrating both static structural and modal analysis methods. Topology optimization via the OptiStruct module was applied to minimize material in low-stress regions. Following structural optimization, modal analysis was conducted to determine the natural frequencies and evaluate dynamic behavior under real-world conditions. The optimized design achieved a 9.4% reduction in mass and an 11.5% decrease in peak stress while maintaining the displacement and resonance frequencies within acceptable limits. These results confirm that the proposed approach significantly enhances brake disc performance and durability. This study demonstrates the effectiveness of combining finite element analysis and topology optimization in enhancing both static and dynamic characteristics of motorcycle brake componentsTài liệu tham khảo
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[14]. J. Wu, O. Sigmund, J.P. Groen, Topology Optimization of Multi-Scale Structures: A Review, Struct. Multidiscip. Optim., 63 (2021) 1455–1480. https://doi.org/10.1007/s00158-021-02881-8
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[2]. A. Singh, Design, Analysis & Weight Reduction of Disc Rotor for All Terrain Vehicle Using Topology Optimization, J. Chem. Health Risks, 13 (2023) 226–251. https://doi.org/10.1016/j.jchr.2023.11.007
[3]. P. Sokołowski, P. Magryta, Mass Optimizing of the Brake Disc to Light Tricycle, https://bibliotekanauki.pl/articles/117966.pdf
[4]. S. Thigale, C. Shah, Weight Reduction in Brake Disc Using Topology Optimization, IJRET, 5 (2016) 73–78, https://ijret.org/volumes/2016v05/i10/IJRET20160510037.pdf
[5]. A. Oshinibosi, D. Barton, P. Brooks, C. Gilkeson, Topology Optimisation of an Automotive Disc Brake Rotor to Improve Thermal Performance and Minimise Weight, EuroBrake Technical Programme, 2021 (2021) 1–8. https://doi.org/10.46720/4177245eb2021-ebs-002
[6]. P.G.R. Kulkarni, Design, Analysis and Optimization of Brake Disc Made of Composite Material for a Motor Cycle, Int. J. Res. Publ. Eng. Technol., 3 (2017) 63–69. https://repo.journalnx.com/index.php/nx/article/view/2229/2190
[7]. A.A. Alnaqi, S. Shrestha, D.C. Barton, P.C. Brooks, Optimisation of Alumina Coated Lightweight Brake Rotor, SAE Technical Papers, 2014 (2014) 1–8. https://doi.org/10.4271/2014-01-2501
[8]. J. Tang, D. Bryant, H. Qi, A 3D Finite Element Simulation of Ventilated Brake Disc Hot Spotting, EuroBrake 2016 Conference, Milan, Italy, 13–15 June 2016, https://www.researchgate.net/publication/317166402_A_3D_FINITE_ELEMENT_SIMULATION_OF_VENTILATED_BRAKE_DISC_HOT_SPOTTING
[9]. C.B. Chavan, A.S. More, N.N. Patil, P. Baskar, Static Structural and Thermal Analysis of Brake Disc with Different Cut Patterns, J. Appl. Res. Technol., 16 (2018) 45–56. https://doi.org/10.22201/icat.16656423.2018.16.1.702
[10]. A. Bhat, B. Pal, D. Dandotiya, Structural Analysis of a Two-Wheeler Disc Brake, IOP Conf. Ser.: Mater. Sci. Eng., 1013 (2021) 012024. https://doi.org/10.1088/1757-899X/1013/1/012024
[11]. J. Dewanto, O. Soegihardjo, A.N.R. Wijaya, New Active Cooling System to Prevent an Overheating on the Vehicle Disc Brake, Int. J. Ind. Res. Appl. Eng., 3 (2018) 1–6. https://doi.org/10.9744/jirae.3.1.1-6
[12]. L. Tang, J. Wu, J. Liu, C. Jiang, W.B. Shangguan, Topology Optimization and Performance Calculation for Control Arms of a Suspension, Adv. Mech. Eng., 2014 (2014) 734568. https://doi.org/10.1155/2014/734568
[13]. L. Chang, Simulation Analysis of Finite Element Preprocessing Based on HyperMesh, IWCMC, 13 (2020) 1202–1207. https://doi.org/10.1109/IWCMC48107.2020.9148051
[14]. J. Wu, O. Sigmund, J.P. Groen, Topology Optimization of Multi-Scale Structures: A Review, Struct. Multidiscip. Optim., 63 (2021) 1455–1480. https://doi.org/10.1007/s00158-021-02881-8
[15]. A. Manguri, H. Hassan, N. Saeed, R. Jankowski, Topology, Size, and Shape Optimization in Civil Engineering Structures: A Review, Comput. Model. Eng. Sci., 142 (2025) 933–971. https://doi.org/10.32604/cmes.2025.059249
[16]. Altair Engineering Inc, HyperMesh User Guide 2023, Altair Engineering. https://learn.altair.com/hypermesh
[17]. R.C. Hibbeler, Engineering mechanics: dynamics, 14th ed., (2016), Pearson Education, New Jersey
[18]. Ministry of Transport (Vietnam), Circular No. 31/2019/TT-BGTVT: Regulations on Speed and Safe Distance for Road Vehicles, issued on September 29, 2019
Tải xuống
Chưa có dữ liệu thống kê
Nhận bài
16/07/2025
Nhận bài sửa
09/08/2025
Chấp nhận đăng
10/09/2025
Xuất bản
15/09/2025
Chuyên mục
Công trình khoa học
Kiểu trích dẫn
Ngo Anh, V., Vu Duy, D., Tran Manh, Q., Vu Quoc, H., & Bui Van, H. (1757869200). Design optimization for material reduction in motorcycle brake discs. Tạp Chí Khoa Học Giao Thông Vận Tải, 76(7), 951-964. https://doi.org/10.47869/tcsj.76.7.3
