Development of a modular brake disc assembly for spot-type disc brake systems with enhanced performance characteristics

This study presents a modular brake disc assembly designed to improve the performance characteristics of automotive spot-type disc brake systems. We examined disc brake system configurations in 2017 fifth-generation Ford Explorer vehicles. Three principal limitations of conventional brake discs were identified: excessive thermal gradients and internal stresses within disc components, non-repairable structural designs, and insufficient heat transfer from friction surfaces during operation. To address these challenges, we employed the theory of inventive problem solving (TRIZ), which led to the development of a modular decomposition approach for principal structural elements of the brake disc. The design process involved 3D modelling techniques within the KOMPAS-3D v21 educational software package, which facilitates comprehensive virtual prototyping and analysis. Finite element meshing and subsequent static strength calculations, using the von Mises criteria, revealed stress-strain distribution zones in the developed components of the modular brake disc assembly. The findings underscore the importance of enhancing structural design and selecting materials with optimal physical properties, including density, yield strength, elastic modulus, and thermal conductivity. This approach would reduce the inertial masses of components and the unsprung masses of the vehicle, while increasing the guaranteed safety factor and improving heat dissipation from the friction pairs in spot-type disc brake systems. In addition, 3D printing methods with wax-like filaments, essential for investment casting in steel production, were reviewed and applied. The study demonstrates that the selection of optimal materials enhances braking efficiency and reduces the stopping distance and time of a vehicle when using the proposed design. Recommendations for print settings and modes are also provided.