Design Development of Lightweight Disc Brake for Regenerative Braking – Finite Element Analysis

The automotive industry has for many yearsidentified weight reduction as a way of improving productcompetitiveness and thus the ability to make profits. One areathat has been examined for weight reduction is vehicle withregenerative braking system (RBS). The greatest advantages ofelectric vehicles (EVs), and hybrid electric vehicles (HEVs) istheir ability to recover significant amounts of braking energyusing a RBS. Regenerative braking is an effective method toextend brake disc life, minimise disc rotor weight, minimisebrake pad wear and to extend the working range of an EV orHEV. Regenerative braking would extend the working range ofan EV or HEV provided that any extra energy consumption e.g.from increased vehicle mass and system losses did not outweighthe saving from energy recuperation, also reduce duty levels onthe brakes themselves, giving advantages including extendedbrake rotor and friction material life, but more importantlyreduced brake mass, minimise brake pad wear. The objective ofthis research is to define thermal performance on lightweightdisc brake models. Thermal performance was a key factorwhich was studied using the 3D model in Finite ElementAnalysis simulations. Ultimately a design method forlightweight brakes suitable for use on any car-sized hybridvehicle was used from previous analysis. The designrequirement, including reducing the thickness, would affect thetemperature distribution and increase stress at the critical area.Based on the relationship obtained between rotor weight,thickness, undercut effect and offset between hat and frictionring, criteria have been established for designing lightweightbrake discs in a vehicle with regenerative braking