The design process for a formula student car brake disc

In today's world with fast-growing mobility, everything is becoming more compact day by day with ever-increasing technological advances. This paper deals with the design of a disc brake rotor considering the requirement of the student formula team. In this paper, different design iterations shall be realized to have maximum heat flux distribution and at the same time maintain the structural rigidity of the rotor so that it can withstand the torque requirement of an SAE vehicle especially the acceleration test. Solidworks was used for design modeling while Optistruct and Hypermesh were used to perform the CAE Analysis for the brake rotor. In this paper, we will explain various design iterations and how design can be optimized with extensive use of CAE tools by performing structural and thermal analysis, etc. The analytical results from the CAE simulation will help us to determine the slots and hole pattern on the rotor face as well as material selection for the rotor. The numerical calculation was formed to find required the forces and torque based on the vehicle dynamics inputs. The objective of this paper is the design and optimization of the brake rotor.