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

摘要： 当前底盘零部件轻量化技术是汽车业内传统燃油车及新能源汽车的热门研究方向，制 动盘轻量化对于节能减排、提升续航里程、降低簧下质量等具有积极的作用。为了实现国内 某车型整车对底盘制动模块制定的轻量化目标，文章通过将汽车制动系统中传统灰铸铁制动 盘进行轻量化设计，设计方案是将制动盘盘帽由铸铁材质改为密度更轻的铝合金材质，结合 结构设计以及模拟仿真分析，不仅实现制动盘单件降重约 12%，同时制动盘热变形性能也有 显著提升，对整车轻量化要求提供改善支持，为新型制动盘结构设计提供方向和建议。

关键词: 制动盘；轻量化；铝合金盘帽；结构设计；热变形分析