A Multi-objective Optimization Approach for Automotive Disc Brakes: Integrating Castability, Strength, and NVH

Brake squeal in automotive disc brakes remains a significant quality challenge. This issue is further complicated by design requirements for weight reduction, strength, and manufacturability, which often are conflicting; addressing these factors individually in the current process has led to development rework. In this study, a multi-objective optimization method that accounts for brake squeal in the early design stage was established, targeting objectives related to structural strength and stiffness, noise and vibration and harshness (NVH), and castability. Although castability evaluation typically relies on large-scale fluid dynamic analyses, a heat transfer analysis was introduced from an analogical perspective to enhance efficiency. Furthermore, since brake squeal is a bifurcation phenomenon exhibiting discrete characteristics, an evolutionary algorithm (an AI-based optimal solution search method) was employed.