Fluid Topology Optimization for Heat Dissipation of Ventilated Brake Discs

Enhancing the heat dissipation performance of ventilated brake discs is a complex challenge involving fluid dynamics, solid mechanics, rotational motion, thermal transfer, and frictional interactions. To address this issue, this study developed a comprehensive simulation model for brake disc heat dissipation, informed by wind tunnel testing conducted on a multi-purpose vehicle (MPV) model. The research included a sensitivity analysis of design parameters related to the brake disc blades and employed a topology optimization approach to enhance the disc's heat dissipation capabilities. The study successfully demonstrated the applicability of topology optimization to the intricate thermal simulation of brake discs. As a result, a novel brake disc blade design with a unique geometry was developed, and the underlying principles contributing to its improved thermal performance were thoroughly analyzed. The optimized brake disc design, distinguished by a carefully contoured inlet curve and a constricted outlet port structure, achieved superior heat dissipation. This was accomplished by reducing flow separation and increasing pressure within the flow channel, all while maintaining the mass flow rate.