  Design calculation and analysis have been performed for the brake disc along
with the design calculations for the brake caliper for the system optimization,
and design of experiments have been implemented for the brake disc in order to
optimize the performance of the braking system. Ventilated disc brake with an
outer diameter of 175 mm has been used for the system level analysis and 83 %
performance efficiency has been achieved after all the proper validations and
analysis. Stainless Steel (SS-410) material configuration has been considered
for the disc brake and performance enhancement of ventilated disc brake has
been carried out using Matlab, Ansys, and Solidworks. The brake disc is going
to be deployed as a common brake disc in the rear part of the All-terrain
vehicle, and is responsible for providing effective rear wheel locking, and
piaggio double piston fixed calipers have satisfied the piston diameter for the
wheel locking conditions at rear wheels with DOT-4 Brake fluid in the master
cylinder in order to provide the effective braking. The rear disc brake is
fixed on the gearbox output shaft and a caliper mount is welded on a rear
member of the roll cage. A mathematical model has been formulated for carrying
out Multi-objective genetic algorithm optimization, which has resulted, a newly
designed brake disc is optimum in terms of weight, factor of safety, thermal
dissipation, equivalent stress, vibration with enhanced airflow behavior.
Converged residual plots have been obtained in computational fluid dynamics
simulation by using 2nd-degree order to validate the CFD models, and in order
to meet the frequency of rear disc brake to firing frequency of engine, design
constraints of the brake disc have been optimized in terms of vibration along
with considering the other parameters.
