IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 14, Issue 2 Ver. III (Mar. - Apr. 2017), PP 72-80 www.iosrjournals.org DOI: 10.9790/1684-1402037280 www.iosrjournals.org 72 | Page Topology Optimization of Automotive Disc Brake using FEA-DOE Hybrid Modeling Vineshkumar S Prajapati 1 , Aniruddh R Kyada 2 , Dr. Tushar M Patel 3 1 M.E. Scholar, Mechanical Engineering Department, LDRP-ITR, Gandhinagar, India 2 Assistant Professor, Mechanical Engineering Department, LDRP-ITR, Gandhinagar, India 3 Professor, Mechanical Engineering Department, LDRP-ITR, Gandhinagar, India Abstract: The objective of this Paper is to find the performance parameters of the disc brake system using experimental and statistical approach. A standard energy (DOE) design of experiments by Taguchi method is applied to study three performance parameters each with three levels. The Hole diameter, No. of pattern and Distance between hole becomes the design variables. The disc brake model is to be developed in creo 2.0 and analysed using ANSYS. The number of parameters and levels are more so probable models are too much and which consumes more time. To overcome this problem TAGUCHI method along with FEA is used. The reduction of temperature and weight is achieved by providing cross-drill hole. The orthogonal array is used by taking variable parameters. Then FEA is performed on those models to get the best solution. Keywords: Parametric optimization, Disc brake, FE Analysis, FEA-Design of Experiments, Temperature reduction, Weight reduction I. Introduction The most significant safety device in vehicle is its braking system, which slows down the vehicle very quickly. There are many types of brakes are used in automobile works on the same principle. Brakes are energy converting machine elements which converts braking energy into heat energy and this heat is dissipated into the surrounding. Using different numerical and experimental approaches the disc brake design is progressing. However, brake performance still needs much work to carry out. This is due to the fact that disc brake performance strong depending on many parameters including materials and geometry of brake components, component interaction, many operating and environmental conditions. The main objective of the research is to reduce the weight of the disc brake and reduce the generated temperature. This optimized design is being constrained by the minimum stress. The disc brake is analysed using the finite element technique, appropriate model of the disc brake is to be developed. The high temperature generated in solid type disc brake is reduced by providing a cross drilled hole. Then FEA is performed on those models to get the best solution. The numbers and levels of parameters are more; the probable models are too many. So, to select optimum parameters among them large numbers of modelling and analysis work is involved which consumes more time. To overcome this problem, Design of Experiment technique is used along with FEA. II. Literature review In the past, several researchers have studied the optimization of performance of disc brake by the Taguchi’s method of Design of experiments (DOE) to reduce the computational effort without affecting the final solution quality. Mostafa et al. (2013) analysed the disc brake using brake dynamometer and used Taguchi approach for DOE. The applied pressure, wedge angle inclination, speed of the vehicle was considered as control factors with three levels of each. By the S/N ratio graph and ANOVA analysis result the most effective parameter on brake performance were identified. The Taguchi method reduces time and experimental costs by minimizing the experiments. They concluded that by using Taguchi Approach the applied pressure and wedge angle were the most effective parameters for estimating the disc brake [1]. Nouby et al. (2013) evaluated disc brake experimentally using brake dynamometer and used Taguchi approach. For prediction of operation parameters which affect the performance of disc brake the Taguchi Method was utilized. An L16 orthogonal array was performed by taking applied pressure, speed of vehicle, angle inclination of wedge and water spraying as control factors with four levels. The important parameters to improve wedge type disc brake behaviour were defined by S/N ratio graph. The experimental results performed by dynamometer were compared with the predicted results using Taguchi approach [2]. Patel et. al. (2013) used Taguchi method to reduce the weight of the chassis frame of Eicher 11.10 chassis frame and FEA was performed to obtain the best solution for chassis frame [3]. Singh et al. (2014) identified three control factors were back plates thickness, slots width and slots angle, for each higher and lower levels and L8 orthogonal array was performed with the S/N ratio. ANOVA was utilized to analyse the effect of selected process parameters along with their levels of impact. They have