Research On The Light-weight Optimization Of Disc Brake Structure Based On CAE

Disc brake is an important part of brake system.With the development oftechnology and the requirement of people’s life,and with its excellent brakeperformance,it’s been used on more and more cars. The current Chinese automobilefuel consumption accounted for the entire oil consumption1/3, it has beenestimated that by2020this proportion will rise to57%. Therefore, the automobileenergy saving is closely bound with our national overall energy consumption. Asan important means of automobile energy saving,light-weight technology has beenused by many automobile manufacturers. As one of the key parts of the car,light-weight of disc brake is the future development direction.In this paper, a disc brake as the research object, using the finite elementsoftware to do the analysis of stress and deformation of the parts, and s et thepressure volume calculation of pre-optimization disc brake, to ensure that theymeet the stiffness requirements. Then operate the topological optimization designon the shell through finite element software, remesh the optimized shell andimplement stress and deformation analysis, finally carries on the pressure volumecalculation, ensure that the optimized disc brake meets the stiffness requirements.First,building the finite element model of caliper disc brake by HyperMeshsoftware， including shell,anchor,disc,pad and so on.In order to improving thequality of mesh,different methods are used.Providing different materials, buildingcontact surfaces,tie,boundary conditions and load.Then with the help of ABAQUS tool, using pressure volume calculati onmethod to calculate the stiffness of disc brake shell. Form the stress anddeformation nephograms of the shell, we know the maximum stress of the shelloccurs on the punch side, which is396MPa, no more than the allowable stress ofthe upper limit of steel; the maximum deformation appeared in the shell at thebottom of the oil cylinder, which is0.26mm. and the pressure volume is6.8407x102mm3, which is slightly bigger than the experimental results of6.7314x102mm3, assembly meets the stiffness requirements.Then based on the OptiStruct software to implement the disc brake of thetopological optimization. After completing the prepartion of topologicaloptimization, topology optimization through OptiStruct software,the quality ofshell has been reduced to1.6kg from4.8kg, lightened about66.6%. Finally, remesh the optimized geometric model, and complete the stress anddeformation analysis, then calculate the pressure volume calculation of optimizeddisc brake, which is9.2598x102mm3,slightly bigger than the experimental resultsof9.0561x102mm3, the optimized assembly meets the stiffness requirements.