Design and Analysis of Active Cooled Brake Disc in Lattice Structure for Additive Manufacturing

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.

Keywords

• Additive manufacturing
• Lattice structures
• Brake disc
• Effective cooling
• Braking distance

Kafes Yapıda Etkin Soğutmalı Fren Diskinin Eklemeli İmalat için Tasarımı ve Analizi

Abstract

Otomotiv, havacılık ve raylı sistemlerde şüphesiz en önemli parçalarından biri fren diskleridir. İlk olarak 1950’li yıllarda kullanılmaya başlanılan diskli fren sistemleri günümüz teknolojisine gelene kadar birçok gelişme gösterse de hala geliştirilmesi devam eden sistemlerdir. Sürtünmeli fren sistemlerinde ısı açığa çıkar. Bu sıcaklık belli bir düzeyin üzerine çıktığında sürtünme elemanı olan balataların özellikleri sebebi ile sürtünme katsayıları azalır. Uzun frenleme (ağır tonajlı araçlarda yokuş aşağı ya da spor araçlarında zorlu parkurlarda) taşıtın durma mesafesini arttırmakta, fren ve teker grubu ekipmanlarının kullanım ömürlerinin azalmasına sebep olmaktadır. Bu sebepten hem sürüş emniyeti hem de taşıt güvenliği açısından fren soğutma yapısı önem arz etmektedir. Bu çalışmada, bir spor arabada kullanılmak üzere geleneksel imalat metotlarına göre tasarlanmış örnek bir fren diskinin soğutma performansının arttırılması ve ağırlık olarak hafifletilmesi için kafes yapı modelleme yaklaşımı uygulanmıştır. Tüm tasarım yaklaşımları, eklemeli imalat teknolojilerinin sunduğu yenilikçi imkân ve kabiliyetler göz önünde bulundurularak ele alınmıştır. İterasyonlar sonucu elde edilen model eklemeli imalat metotlarından seçici lazer ergitme yöntemi ile imal edilecek şekilde ele alındığında kütlece %20 daha hafif, Von-mises gerilmeleri bakımından da %35 daha düşük gerilmeye sahip bir model ortaya çıkmıştır. Ele alınan standart ve kafes yapıda disklere eşit ısı yüklemesinde standart disk yüzeyinde 440 ℃ sıcaklık bulunurken yapılan optimum tasarımda 213 ℃ sıcaklık belirlenmiştir.

Keywords

• Eklemeli imalat
• Kafes yapılar
• Fren diski
• Etkin soğutma
• Fren mesafesi

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