Static Structural Analysis: Verifying Automotive Brake Rotor Reliability

Created the high-fidelity brake rotor CAD geometry in SolidWorks, ensuring precise slots and ventilation structures. The model was then imported cleanly into ANSYS Mechanical, performing necessary geometry cleanup to prepare the component for high-fidelity finite element meshing.

Generated a refined finite element mesh, optimizing element size and density specifically in the critical high-stress areas (e.g., ventilation holes) to ensure the accuracy of the static structural analysis results without unnecessary computational overhead (S_R3).

Applied realistic operational constraints, including fixed supports at the hub connection points and the specified maximum braking torque/pressure loads to simulate the worst-case scenario. This accurately established the virtual testing environment for structural stress analysis (S_R4).

Executed the ANSYS Static Structural solver to determine the resultant Von Mises stress, strain, and displacement across the entire rotor body. This phase confirmed the structural response matched theoretical predictions under the extreme braking load.

Extracted and post-processed the critical results, calculating the Factor of Safety (FOS) and identifying the maximum displacement. This step verified the design’s margin of error and structural reliability against material yield strength, ensuring compliance (S_R4).

Delivered the complete simulation project files, a formal validation report, and clear, actionable insights into the brake rotor’s structural reliability, confirming the suitability of the client’s theoretical design.