Multi-Physics Coupling-Driven Structural Design of Lightweight Brake Discs for New Energy Vehicles

在“碳达峰”与“碳中和”的战略目标下，新能源汽车轻量化技术成为关键发展方向。制动盘作为簧下质量的核心部件，其轻量化设计对整车性能提升具有重要意义。本研究旨在基于碳化硅颗粒增强铝基(SiCp/A356)复合材料，设计一种高性能轻量化制动盘结构。通过Star CCM+仿真平台建立制动盘流场模型，分析六种不同散热筋结构对制动系统流场行为的影响，并对比流场分布形态和表面传热系数等参数。筛选最优散热筋构型后，基于ANSYS APDL平台构建多物理场耦合数值分析体系，集成传热学、流体力学与结构力学模型，对制动盘结构进行全工况仿真与迭代优化。研究表明，散热筋几何构型显著影响制动盘散热性能，优化后的结构在流场分布和传热性能上均表现优异。多物理场耦合分析进一步验证了该结构在热力学性能与机械强度方面的可靠性，最终确定的轻量化制动盘设计方案满足实际应用需求，兼具仿真效率与工程可行性，有助于进一步提升新能源汽车制动系统性能。Under the strategic goals of “carbon peak” and “carbon neutrality,” lightweight technology for new energy vehicles has emerged as a critical development direction. As a core component of unsprung mass, the lightweight design of brake discs holds significant importance for enhancing overall vehicle performance. This study aims to develop a high-performance, lightweight brake disc structure based on silicon carbide particle-reinforced aluminum matrix (SiCp/A356) composites. Using the Star CCM+ simulation platform, a flow field model of the brake disc was established to analyze the influence of six different cooling rib structures on the flow behavior of the braking system, with comparisons made on parameters such as flow field distribution patterns and surface heat transfer coefficients. After selecting the optimal cooling rib configuration, a multi-physics-coupled numerical analysis framework was constructed on the ANSYS APDL platform, integrating heat transfer, fluid dynamics, and structural mechanics models to perform full-scenario simulations and iterative optimization of the brake disc structure. The research demonstrates that the geometric configuration of cooling ribs significantly impacts the thermal dissipation performance of the brake disc, with the optimized structure exhibiting superior flow field distribution and heat transfer efficiency. The multi-physics-coupled analysis further verifies the reliability of this structure in terms of thermodynamic performance and mechanical strength. The finalized lightweight brake disc design meets practical application requirements, balancing simulation efficiency and engineering feasibility, thereby contributing to the further enhancement of braking system performance in new energy vehicles. This translation maintains an academic tone suitable for journal publications, ensuring technical accuracy while adhering to formal scientific writing conventions.