Fea-Based Comparison of Topologically Optimized and Human-Designed Brake Systems for Thermal Optimization

Khoo, Garion Yi Jun (2026) Fea-Based Comparison of Topologically Optimized and Human-Designed Brake Systems for Thermal Optimization. Final Year Project (Bachelor), Tunku Abdul Rahman University of Management and Technology.

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Abstract

This thesis investigates the thermal optimization of brake systems using Finite Element Analysis (FEA), comparing topologically optimized (TO) designs with human-designed counterparts for disc brakes (Aluminium 6061) and brake callipers (Aluminium 7068). Utilizing Ansys 2024 R1, simulations under Formula SAE conditions revealed that the TO disc brake reduced average temperature from 428.65°C to 411.31°C (-4.05%), increased maximum heat flux from 3.32×10⁵ W/m² to 8.0475×10⁵ W/m² (+142.38%), increased deformation from 0.00236 mm to 0.242 mm (+10155.93%), and raised equivalent stress from 7.4602 MPa to 235.85 MPa (+3062.27%) while lowering the mass by 29.805% of its original mass. For the brake calliper, TO reduced average temperature from 430.07°C to 429.98°C (-0.021%), boosted maximum heat flux from 1.976×10⁵ W/m² to 2.8435×10⁵ W/m² (+69.492%), increased deformation from 0.347 mm to 1.8203 mm (+524.582%), and decreased equivalent stress from 1638.7 MPa to 613.75 MPa (-266.998%) while lowering the mass by 15.693% of its original mass. These refinements, validated through iterative design, underscore TO’s potential for lightweight, high-performance brake systems suited for additive manufacturing and sustainable automotive applications