Design, Analysis & Weight Reduction of Disc Rotor for all Terrain Vehicle Using Topology Optimization

Abstract

This research paper presents a comprehensive study on the design, analysis, and weight reduction of a disc rotor for an All Terrain Vehicle (ATV) through the application of topology optimization techniques. In the context of modern engineering and vehicle design, the demand for enhanced performance, fuel efficiency, and overall sustainability has necessitated the development of lightweight yet structurally robust components. The disc rotor, a critical component in the ATV's braking system, is a prime candidate for optimization to achieve these objectives. The study begins by providing an overview of the challenges and requirements associated with disc rotor design for ATVs, emphasizing the need for enhanced performance and weight reduction. To address these challenges, topology optimization, a cutting-edge design methodology, is employed. This approach leverages advanced computer-aided design and finite element analysis tools to systematically explore and redefine the component's internal structure while ensuring it retains its mechanical integrity and braking efficiency. The methodology involves creating a finite element model of the disc rotor, specifying the loads and boundary conditions, and utilizing mathematical algorithms to iteratively remove material from non-critical areas, thereby reducing weight while preserving structural integrity. The study evaluates the disc rotor's performance in terms of stress distribution, heat dissipation, and overall efficiency, comparing it to conventional designs to highlight the benefits of the proposed topology-optimized rotor. The findings of this research are expected to contribute significantly to the field of ATV design and automotive engineering, offering insights into the application of topology optimization for weight reduction and improved performance of critical components. The optimized disc rotor design showcased in this study can potentially lead to reduced fuel consumption, enhanced braking capabilities, and increased vehicle manoeuvrability while maintaining safety standards. Furthermore, this research demonstrates the feasibility and advantages of utilizing topology optimization techniques in the development of lightweight and structurally efficient components for a wide range of applications beyond ATVs, thus promoting sustainable engineering practices.