Design Analysis & Topology Optimization of Passenger Car Disc Brake Anjali Ashok Shinde (1) ME (Design) Mechanical Engineering JSPM’s - R.S. College of Engineering, Pune, Maharashtra Prof. Shailesh S Pimpale (2) Mechanical Engineer Department JSPM’s - R.S. College of Engineering, Pune, Maharashtra Dr. Subim N. Khan (3) Mechanical Engineering Department JSPM’s - R.S. College of Engineering, Pune, Maharashtra Abstract- The disk brake may be a device for slowing or stopping the rotation of a wheel. Generally repetitive braking system of the automobile cars results in heat generation during each braking event. The brake disc brake 3D model prepared by CATIA software. Finite Element modal analysis of automobile 4 wheeler disc brake is performed to determine mode shapes and natural frequencies and also static analysis is performed to obtain optimized model from topology optimization technique from ANSYS 19 software. Hence, experimental testing using FFT analyzer technique (impact hammer and accelerometer) is performed to determine mode shapes and natural frequency and comparison of results with numerical results. Keyword - Disc Brake, Topology Optimization, FFT Analyzer. I. INTRODUCTION The racing fans involved will surely know the importance of good brakes not just for safety but also for staying competitive. The disk brake may be a device for slowing or stopping the rotation of a wheel. A brake disc usually made from forged iron or ceramic composites includes carbon, Kevlar and silica, is connected to the wheel and therefore the axle, to prevent the wheel. A friction brake generates frictional forces as two or more surfaces rub against one another, to scale back movement. Based on the planning configurations, vehicle friction brakes are often grouped into drum and disc brakes. The main component of the braking system is the disk brake. Its performance directly affects the driving safety of the vehicle. When the vehicle is braking, the excitation frequency is close to the natural frequency of the brake disk, which will cause resonance, generate severe vibration & noise & affect ride comfort. Therefore, it is necessary to analyses modal characteristics of disk brake. TATA Sumo 800 Lacer car disc brake was taken for experimental study purpose. The brake disc (or rotor) is that the rotating a part of a wheel's disk brake assembly, against which the restraint are applied. The material is usually gray iron, a sort of forged iron. The weight and power of the vehicle determines the necessity for ventilated discs. Fig 1.TATA Sumo 800 Lacer Car Disc Brake II.PROBLEM STATEMENT Nowadays, topology optimization technique is used for weight optimization of components which reduces material cost and manufacturing. In present research 4- wheeler disc brake is to be studied under FEA to determine the optimum material removal from existing 4- wheeler disc brake under existing boundary condition and also determine changes in von misses stress and deformation with tautologized model. Natural frequencies are calculated to determine the nature of mode shapes at respective frequencies III.METHODOLOGY The methodology involves the technology utilized for performing the designing and analysis of the object. • Design of 4 wheeler disc brake • Dimension specification • Analysis of disc brake by ANSYS • Static structural analysis & Modal Analysis for mode shape. • To perform static structural analysis of disc brake under existing boundary condition to obtain deformation and von misses stress and optimized model from topology optimization. • The best optimized is to be obtained from topology optimization technique and compared to the existing model. International Journal of Engineering Research & Technology (IJERT) ISSN: 2278-0181 http://www.ijert.org IJERTV9IS060752 (This work is licensed under a Creative Commons Attribution 4.0 International License.) Published by : www.ijert.org Vol. 9 Issue 06, June-2020 1557