Optimization of ceramic composite material disk brakes design for automotive applications: A study on lightweight structure, efficiency, and mechanical durability

This research aims to investigate the utilization of composite materials in the vehicle industry by manufacturing the disk brakes. The vehicle industry persistently searches for augmenting efficiency through the integration of innovative technologies, enhancing performance and minimizing the cost to increase riding safety and comfort. In this work the strong adhesive epoxy is employed as a binder matrix to fabricate disk brakes. The reinforcing agents include high strength, high hardness, heat resistance, and high thermal conductivity ceramic powders, such as alumina and zinc oxide. The hybrid composite material characteristics were assessed via experimental tests, which included tensile, hardness, impact, wear, and friction tests. A finite element analysis via ANSYS 2023 R2 software and solid work 22 were used for further scrutiny of the experimental tests. The finite element model of the composite sample was used to determine the optimal mechanical properties. The investigation involves the analysis of von-Misses stress, total deformation, equivalent elastic strain, and strain energy. A comparative analysis was performed on the results obtained with a disk brake made of structural steel and gray cast iron as traditional materials.