关键词: 制动盘；轻量化；铝合金盘帽；结构设计；热变形分析

Abstract: The current lightweight technology for chassis components is a popular research direction in traditional fuel vehicles and new energy vehicles in the automotive industry. Lightweight brake discs have a positive effect on energy conservation and emission reduction, improving range, and reducing unsprung mass. In order to achieve the lightweight goal of chassis brake module for a certain vehicle model in China, this article proposes a lightweight design of traditional gray cast iron brake discs in the automotive brake system. The design scheme involves changing the brake disc cap from cast iron material to a lighter density aluminum alloy material, combining structural design and simulation analysis. This not only reduces the weight of a single brake disc by about 12%, but also significantly improves the thermal deformation performance of the brake disc. This provides improvement support for the lightweight requirements of the vehicle, and provides direction and suggestions for the design of a new type of brake disc structure.

Key words: Brake disc; Lightweight; Aluminum alloy; Structure design; Thermal deformation analysis