International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 11 Issue: 11 | Nov 2024
p-ISSN: 2395-0072
www.irjet.net
Lightweight 6-Piston Caliper Optimization Using Generative Design for Enhanced Performance and Safety Sunny Patel, Miten Naliyadhara, Dip Chaklashiya, Shubham Jogani, Dharmik Chodvadiya, Jeel Savaliya ---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - This paper looks at how a redesigned 6-piston
brake caliper can improve braking efficiency, reduce weight, and enhance performance in mid-size SUVs, which typically weigh between 1800–2700 kg. By using generative design software Fusion 360, we created a new brake system with a 6piston fixed caliper that offers better clamping force and heat management. The brake disc was also optimized to reduce weight and improve heat dissipation. The new caliper is light weighted and reduces weight from the vehicle’s unsprung weight. This weight reduction improves suspension performance, making the vehicle more responsive and stable while also reducing stopping distance.These changes lead to safer, more efficient braking. Key Words: Generative Design,6-Piston Caliper, Braking Efficiency, Weight Reduction
1.INTRODUCTION The braking system is essential for vehicle safety, especially for mid-size SUVs like the Ford EcoSport, Hyundai Tucson, and Toyota Fortuner, which typically weigh between 1800– 2700 kg. This study focuses on redesigning the brake system by changing the floating caliper to a fixed 6-piston caliper using advanced generative design technology. The goal is to make the braking system lighter, more efficient, and improve its performance. A 6-piston caliper design provides better braking force and heat management, which is important for heavy loads and high-speed braking. The brake discs were also improved with features like fins and holes to help cool the system and reduce weight. The result of using a lighter caliper is a decrease in the overall weight of the braking system, which enhances vehicle handling and safety by improving suspension performance and reducing the stopping distance.
Fig -1: 6 piston brake caliper and brake disc
brake disc The brake disc is crucial in braking as it dissipates heat and provides a rough surface for better braking performance. Features like fins between the plates and patterned holes enhance heat dissipation, ensuring smoother braking. The disc must withstand the high clamping force of a 6-piston caliper, making material optimization essential. By reducing its weight from 9.5 kg to 7.8 kg and increasing thermal conductivity compared to conventional materials, the disc becomes lighter and more efficient while maintaining durability and performance.
2. 6-Piston Brake Caliper and brake disc A 6-piston brake caliper is an upgrade from the common 2- or 4-piston systems typically found in compact and mid-size SUVs, like the Ford EcoSport, Hyundai Tucson, and Toyota Fortuner, which weigh between 1800–2700 kg. These calipers have three pistons on both the inboard and outboard sides in a fixed-position design, providing improved clamping force and even pressure distribution across the brake pad. This design is ideal for handling heavier loads, towing, and aggressive high-speed braking, offering better heat dissipation for consistent and reliable performance.
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