Analysis and optimisation of disc brake calipers

摘要

Disc brake calipers are subjected to complex mechanical loading and interaction ofindividual components in a typical brake assembly makes design improvement verychallenging.To analyse caliper behaviour, complex Finite Element models were created andsuccessfully validated using a variety of experimental techniques, includingexceptionally suitable Digital Image Correlation. A novel methodology to optimisecaliper design was developed, using non-linear contact Finite Element Analysis andtopology optimisation, to generate lightweight, high performance brake calipers. Themethod was used on a Formula 1 brake assembly and significant improvement instructural design was achieved, with the new caliper being lighter and stiffer than theoriginal. The same approach was used on more conventional 4 pistons calipers usingvarious boundary conditions with particular focus on mass reduction and considerablylighter designs were achieved. The influence of specific features of the optimisedcalipers on the structural performance was also successfully investigated.