Topology optimization for heat-dissipation rib structure of disc brakes based on thermo-mechanical and modal analysis

In recent years, the braking noise of disc brakes has remained a focal point in research. However, there is a paucity of discussion regarding the improvement of the heat-dissipation rib structure of brake discs through topology optimization methods. This study aims to mitigate the braking noise of disc brakes by constructing a thermo-mechanical coupling and complex eigenvalue analysis model for the brake friction pair. Topology optimization was performed on the heat-dissipation ribs of the brake disc, culminating in a Y-shaped heat-dissipation rib structure. The findings reveal that the Y-shaped structure can augment the heat-dissipation area, enhancing heat dissipation, and substantially reduce the temperature at various key nodes. Moreover, the alteration in the stiffness distribution of the brake disc results in an average increase of 4.9% in the first four-order modal frequencies. This enables the vibrations of the brake disc to evade sensitive noise frequency bands, and renders the distribution of the instability coefficient more concentrated and smoothly. The maximum deformations of the first four modes decrease by 8.9%, 8.1%, 6.9%, and 9.7% respectively, effectively modifying the vibration characteristics.