Optimal design of the disc vents for high-speed railway vehicles using thermal-structural coupled analysis with genetic algorithm

Braking devices are devices that convert kinetic energy into thermal energy using frictional force. A disc-type brake uses the frictional force to brake and can be used in a wide range of applications, such as automobiles, railway vehicles, and aircraft. However, heat dissipation of the disc has been considered a major problem. High temperatures during the braking process cause thermal stress and deformation problems of the disc because the physical properties of metal composing the disc change drastically with temperature. In this study, vents were applied on the disc surface to increase their heat dissipation performance. In general, vents are structurally susceptible to stress and deformation. However, heat dissipation is essential because the disc surface rises to high temperatures. Therefore, a thermal-structural coupled analysis was performed using the computational fluid dynamics and finite element method methods. Five different rotational speeds and surface temperatures of the disc were considered. Design of experiments was used to determine an optimized design utilizing the data from the coupled analysis, and Latin hypercube sampling was used to generate samples from a set of N regions. And the genetic algorithm was used to conduct a sensitivity analysis of the design parameters. The optimized design was determined for harsh conditions. The diameters of vents were selected 6.87 mm, 6.12 mm, and 5.99 mm in a radial direction through the optimization. Thermal stress and deformation acting on the disc were reduced in the optimally designed disc. The optimized disc model experiences a 7.01% decrease in maximum equivalent stress when compared to the original disc. The model also decreased by 7.63% in maximum equivalent elastic strain. So, through enhanced convection-induced heat dissipation, the vents can be considered as a new way to prevent problems with the thermal stress and deformation that were apparent at high temperatures.