Design optimization for material reduction in motorcycle brake discs

Brake discs are essential components in motorcycle braking systems, where structural strength and thermal stability significantly affect vehicle safety and performance. However, conventional brake disc designs often encounter trade-offs between weight reduction and mechanical durability. This study aims to analyze and optimize the design of a motorcycle brake disc to reduce weight and stress while maintaining structural integrity and performance. A standard disc model from the HONDA LEAD (SCR) was reconstructed and analyzed using Altair HyperMesh, integrating both static structural and modal analysis methods. Topology optimization via the OptiStruct module was applied to minimize material in low-stress regions. Following structural optimization, modal analysis was conducted to determine the natural frequencies and evaluate dynamic behavior under real-world conditions. The optimized design achieved a 9.4% reduction in mass and an 11.5% decrease in peak stress while maintaining the displacement and resonance frequencies within acceptable limits. These results confirm that the proposed approach significantly enhances brake disc performance and durability. This study demonstrates the effectiveness of combining finite element analysis and topology optimization in enhancing both static and dynamic characteristics of motorcycle brake components