Disc brake calipers are subjected to complex mechanical loading and interaction of
individual components in a typical brake assembly makes design improvement very
challenging.
To analyse caliper behaviour, complex Finite Element models were created and
successfully validated using a variety of experimental techniques, including
exceptionally suitable Digital Image Correlation. A novel methodology to optimise
caliper design was developed, using non-linear contact Finite Element Analysis and
topology optimisation, to generate lightweight, high performance brake calipers. The
method was used on a Formula 1 brake assembly and significant improvement in
structural design was achieved, with the new caliper being lighter and stiffer than the
original. The same approach was used on more conventional 4 pistons calipers using
various boundary conditions with particular focus on mass reduction and considerably
lighter designs were achieved. The influence of specific features of the optimised
calipers on the structural performance was also successfully investigated.
| Identifer | oai:union.ndltd.org:CRANFIELD1/oai:dspace.lib.cranfield.ac.uk:1826/10196 |
| Date | January 2010 |
| Creators | Sergent, Nicolas |
| Contributors | Tirovic, Marko |
| Publisher | Cranfield University |
| Source Sets | CRANFIELD1 |
| Language | English |
| Detected Language | English |
| Type | Thesis or dissertation, Doctoral, PhD |
| Rights | © Cranfield University, 2010. All rights reserved. No part of this publication may be reproduced without the written permission of the copyright holder. |
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