This research work focuses on optimal design of a disc-type magneto-rheological (MR) brake that can replace a conventional hydraulic brake (CHB) of middle-sized motorcycles. Firstly, a MR brake configuration is proposed considering the available space and the simplicity to replace a CHB by the proposed MR brake. An optimal design of the proposed MR brake is then performed considering the required braking torque, operating temperature, mass and size of the brake. In order to perform the optimization of the brake, the braking torque of the brake is analyzed based on Herschel-Bulkley rheological model of MR fluid. The constrain on operating temperature of the MR brake is determined by considering the steady temperature of the brake when the motorcycle is cruising and the temperature increase during a braking process. An optimization procedure based on finite element analysis integrated with an optimization tool is employed to obtain optimal geometric dimensions of the MR brake. Optimal solution of the MR brake is then presented and simulated performance of the optimized brake is shown with remarkable discussions.
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