Development of a Lightweight Brake Piston for Passenger Car

• Published in: Journal of Power System Engineering Vol. 28; no. 2; pp. 3 - 10
• Main Authors: Jang, Si-Hwan, Lee, Kwon-Hee
• Format: Journal Article
• Language: English
• Published: 한국동력기계공학회 30.04.2024
• Subjects: 기타공학; Durability; Injection Analysis; Weight Reduction; Design of Experiments (DOE); Brake Piston
• ISSN: 2713-8429; 2713-8437
• DOI: 10.9726/kspse.2024.28.2.003

Recently, to respond to strengthened regulations of each country, automobile manufacturers are increasingly interested in weight reduction when developing each part. As a result, related companies strive to reduce the weight by substituting existing materials or changing manufacturing methods, regardless of the body, chassis, and powertrain. In this study, the piston, a part of the disc brake made of cast iron, was changed to plastic material, and the performances were investigated by the numerical analysis and test. The development of the new brake piston was conducted through the base design, injection analysis, static strength analysis, and durability tests. The material of the new brake piston is polyphenylene sulfide (PPS), and the optimal process conditions were suggested by applying the design of experiments in consideration of the deviation of shrinkage rate, which is one of the main performances in the injection process. In addition, this research performed the strength analysis of the piston using FE analysis and evaluated the durability performance through the tests. The weight of the final proposed piston was reduced by 80.2% from the existing 700 g to 138.7 g. The Moldex3D, an injection analysis program, and the Abaqus, a structural analysis program, were used for CAE in this process. KCI Citation Count: 0