关键词: Brake disc, Bionic design, Laser machining, Disc thickness variation, Residual stress, Friction and wear, Vibration and noise 

Abstract: In the automotive and transport industry, braking noise and vibrations are persisting issues and difficult to control. Automotive engineers and researchers are putting considerable effort into overcoming these problems, and significant breakthroughs have been made in this area. In this study, M-shaped grooves were bionically designed and manufactured on the frictional surfaces of four automotive brake discs using a laser machine. Various tests were conducted to characterize the physical and mechanical performance of the modified discs along with their noise and vibration responses. The experimental results demonstrate that discs with laser-machined grooved surfaces have better surface hardness and residual stress reduction than discs with un-grooved surfaces. Significant improvement in the braking performance was observed in terms of disc thickness variation, friction and wear, noise, and vibration reduction. It is concluded that the reduction in braking noise and vibrations is mainly caused by the reduction in the coefficient of friction and wear, increase in damping ratio, and improvement of disc thickness variation of the brake disc by laser surface grooving.

Key words: Brake disc, Bionic design, Laser machining, Disc thickness variation, Residual stress, Friction and wear, Vibration and noise ,