Brake Disc Topology Optimization

Lightweight Formula Student rotor redesigned using topology + FEA validation.

Built a baseline brake disc, ran topology optimization to remove non-critical material, redesigned a manufacturable geometry, then validated it in ANSYS using static structural (Von Mises / deformation) and transient thermal analysis to predict temperature rise during braking events.

Scope CAD Design, Topology Optimization, Structural FEA, Transient Thermal • Client uOttawa Formula Team • Duration 3 weeks • Year 2023
Brake disc — geometry criteria-based design
Topology optimization — material removal
Brake disc — manufacturable redesign

1/7 — Geometry-driven design

/ Challenge

Reduce unsprung mass while ensuring stiffness and safe stresses under braking torque and heat.

/ Solution

Built a baseline rotor CAD, ran SolidWorks topology optimization to identify removable regions, then redesigned a manufacturable geometry and validated performance in ANSYS using static structural and transient thermal simulations.

/ Results

Delivered a lighter disc concept with controlled stress concentrations and limited deformation, plus quantified temperature rise & hotspots over time to support motorsport-oriented design decisions.

> Workflow guided by simulation-driven design

Swipe →
  1. Requirements
    Mounting • pad track
  2. Baseline CAD
    Parametric rotor
  3. Topology
    Keep regions • symmetry
  4. Redesign
    Manufacturable geometry
  5. Static FEA
    Von Mises • deformation
  6. Thermal
    Transient temperature rise
  7. Iteration
    Refine • re-check

Topology optimization

Design space + keep-out regionsSymmetry constraintsMass reduction objectiveInterpretation of load paths

Manufacturable redesign

Fillet strategy (stress relief)Minimum feature sizeConsistent thickness controlBolt-hole integrity preserved

Static structural (ANSYS)

Hub constraints (mounting interface)Tangential braking loadVon Mises post-processingTotal deformation sanity checks

Transient thermal (ANSYS)

Heat flux at pad interfaceConvection on exposed surfacesTemperature vs timeHotspot / gradient tracking
MASS REDUCTION
≈ 15 %
ROTOR GEOMETRY
OD 200 mm · ID 140 mm · thickness 3 mm
STRUCTURAL CASE
Hub constraints · Tangential braking load · Total Hydraulic Pressure
PEAK VON MISES
79.9 MPa (localized)
THERMAL CASE
Transient heat flux at pad interface · Convection on exposed surfaces
PEAK TEMPERATURE
468°C during braking event