This study demonstrates optimal brake disc design to enhance performance in electric vehicles, suggesting improvements in energy efficiency and noise mitigation.
As the ICE vehicle changes into the EV, we can use regenerative brake. It can improve not only the energy consumption but also reduce the hydraulic brake usage. The less hydraulic brake usage mitigates the heat loading on the brake disc. From this reason, the lightweight brake can be used in the EV. However, when the lightweight brake is applied, the brake NVH can be increased. The optimization design of the lightweight brake should be done to prevent the brake NVH. In this paper, the optimal brake disc thickness and brake interfaces are determined by using of disc heat capacity analysis. The lightweight brake should be optimized by using of the brake squeal analysis. We can verify the results from both analysis and test. Finally, we can have the lightweight brake, which is competitive in terms of cost, weight and robust to the brake NVH.
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Kim et al. (2025) studied this question.
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