Parametric Optimization and Transient Analysis of a Disc Brake Using L9 Taguchi Design with Different Brake Materials

In this study, a comprehensive transient structural analysis of a disc brake system is performed to evaluate the mechanical performance under dynamic loading conditions. The focus is on assessing Von Mises stress and total deformation. Three engineering materials, i.e., Tungsten, Inconel 718, and Cast Iron, are considered for the disc brake to determine their suitability based on structural response. The study employs finite element analysis to simulate real-time braking conditions involving rotational velocity and clamping force. To optimize the performance and identify the most influential parameters, the Taguchi method using an L9 orthogonal array is applied. The input parameters considered are clamping force, rotational velocity, and material type (Cast Iron, Inconel 718, and Tungsten), while the output responses are maximum Von Mises stress and total deformation. The simulation results show significant variation in mechanical performance based on material selection and loading conditions. The optimum parameter combination identified was 1500 N clamping force, 500 rpm rotational velocity, and Tungsten as the material.