MECH 4010- Design Project I, Fall 2013

Formula SAE Brake Rotor Optimization

Interim PresentationNovember 28, 2013

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Team #2Alex BurgessKarim ShalohMegan TunneyHanOu Xu

Team Advisor: Dr. Chuang

Agenda Background Requirements Alternative Concepts Analysis of

Alternative Concepts Engineering Analysis Selected Design Budget Project Plan

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(Dalhousie Formula SAE)

Background Brake System

Master CylinderBrake FluidCaliper and Rotor

(Wikipedia-Disc brake)

Brake system schematic(tegger.com)

Rotor

Caliper

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Background Floating Disc

BrakeLateral Degree

of FreedomBetter CanteringRoom for

Expansion (no warping)

Isolates Vibration

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(eliseparts.com)

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Background Dalhousie Formula SAE Current Design

Rotors:○ Front: 250mm Fully Floating Rotor○ Rear: 200m Fully Floating Rotor

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Background Dalhousie Formula SAE Current Design

Carrier○ Designed and Manufactured by the Formula

SAE Team

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Requirements Client

Must withstand a force, of 909 N, locking all tires at 60 km/hr.

Must be compatible ISR 4-Piston Calipers and Tilton 77 Series Master Cylinders

Must include a method of attaching a trigger wheel

Must be compatible with the 2014 hubs and uprights

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Requirements Team

Weigh less than 15% of the current design of 932 g.

Must not exceed allowable budget of $1500.Must have a minimum lifespan of one year.Ensure the safety of the driver and persons

in the surrounding area.

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Alternative Concepts Rotor

Blank

Slotted Drilled and Slotted

Drilled

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Alternative Concepts Carrier

Curved Spoke Slanted Spoke Star Spoke

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Analysis of Alternative Concepts

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Analysis of Alternative Concepts Solidworks Simulations

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Engineering Analysis Material Stress

Clamping Force on RotorRotor and Carrier Material StrengthSafety Factor

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Engineering Analysis Thermal Stress

Temperature During Stop Tests○ 40°C Increase

Material Heat Transfer○ Specific Material

Properties

(NETZSCH Thermal Analysis)

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Engineering Analysis Solidworks Simulations

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Selected Design Rotor Carrier Buttons

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Selected Design Rotor

Stainless SteelSlotted and Drilled

PatternCurved Star

Patterned Spokes

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Selected Design Carrier

AluminumMinimal Extension

from HubSlottedStar Spoke Pattern

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Final Design Buttons

Stainless SteelTwo Pin, Two Plate

DesignWelded Connection

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Budget Quotations Sponsorships Simplifying Design

Performance vs. Budget

Company Product QuoteQuality Machining Services Ltd.

Full Brake Rotor Assembly (1)

$1905.00

Macgregor’s Ltd. Full Brake Rotor Assembly (1)

$1470.50

Specialty Steel Inc. Brake Rotor (1), Brake Carrier(1)

$897.00

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Budget Break Down

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Project Plan Overview

TestingCurrentDesign

End January

Final Design

Mid February

Testing Final Design

March

Theoretical

Practical

Pattern

Materials

Manufacturing

March

Theoretical

Practical

23

Project Plan

TestingCurrentDesign

End January

Final Design

Mid February

Testing Final Design

March

Theoretical

Practical

Pattern

Materials

Manufacturing

March

Theoretical

Practical

24

Project Plan Testing

Theoretical○ Material Stress○ Heat Transfer

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Project Plan

TestingCurrentDesign

End January

Final Design

Mid February

Testing Final Design

March

Theoretical

Practical

Pattern

Materials

Manufacturing

March

Theoretical

Practical

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Project Plan MoTEC Data Acquisition Device Stop Test

Vehicle on StocksReplace FSAE Wheel with Flywheel

○ Mimic Rolling InertiaMeasure Temperature

○ Brake Locking○ Multiple braking Heat Build-up

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Project Plan

TestingCurrentDesign

End January

Final Design

Mid February

Testing Final Design

March

Theoretical

Practical

Pattern

Materials

Manufacturing

March

Theoretical

Practical

28

Project Plan Finalizing Design

PatternMaterial Selection

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Questions?