A study on the optimal design of automotive brake disc rotor using BoxBehnken design and response surface method

In this work, finite element method (FEM) and design of experiment (DoE) were used to design variables based on minimum experimental conditions to cope with the market's high performance requirements for automotive brake disk rotor products. By applying the Box-Behnken Design (BBD) experimental design and the Response Surface methodology (RSM), a four-factor, three-level experimental design and analysis were conducted on four variables, including the vent ratio, cooling fin shape, undercut shape thickness, and undercut angle of the brake disc rotor. A design prediction regression model for the optimal design with high reliability that can predict the correlation with design factors closely related to the dynamic performance of the brake disc rotor was derived. In this study, the BBD method and RSM method were applied to analyze the design and performance of an 18-inch disc rotor, and a design prediction regression model was applied to develop a new 21-inch brake disc rotor, and a reliable performance prediction within 3 % compared to FEM was performed to shorten the design period and identify the correlation between the design variables and the dynamic performance of the disc rotor, which is closely related to the squeal noise generation. Currently, the automotive industry is continuously promoting the establishment of a design and development system to effectively shorten the development period while satisfying the high emotional quality needs of consumers, and aims to improve product competitiveness by applying the results of this research to the field.