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MECH 4010- Design Project I, Fall 2013 Formula SAE Brake Rotor Optimization Design Review

MECH 4010- Design Project I, Fall 2013 Formula SAE Brake Rotor Optimization Design Review. Team #2 Megan Tunney Alex Burgess Karim Shaloh Han Ou Xu Team Advisor: Dr. Chuang. Agenda. Background Scope Requirements Resources Testing Schedule. (Dalhousie Formula SAE). Background.

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MECH 4010- Design Project I, Fall 2013 Formula SAE Brake Rotor Optimization Design Review

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  1. MECH 4010- Design Project I, Fall 2013 Formula SAE Brake Rotor Optimization Design Review Team #2 Megan Tunney Alex Burgess Karim Shaloh Han Ou Xu Team Advisor: Dr. Chuang

  2. Agenda • Background • Scope • Requirements • Resources • Testing • Schedule (Dalhousie Formula SAE)

  3. Background • Brake System • Master Cylinder • Brake Fluid • Caliper and Rotor Caliper Brake system schematic (tegger.com) Rotor (Wikipedia-Disc brake)

  4. Background • Types • Ventilated • Slotted • Drilled 3dcadbrowser.com endless-sphere.com lmfvauxhall.co.uk

  5. Background • Floating Disc Brake • Lateral Degree of Freedom • Better Cantering • Room for Expansion (no warping) • Isolates Vibration (eliseparts.com)

  6. Scope • Optimizing the current Formula SAE Brake Rotor Design • Materials – Alloys with better property • Weight – Reduce on thickness • Heat Transfer – Temperature increases during race • Machining – Best if the machine shop can do it • Compatible with ISR 4-Series Calipers and Tilton 77 Series Master Cylinder ISR 4-Series Caliper (22-048) (www.isrbrakes.se) Tilton 77 Series Master Cylinder (Tilton Master Cylinder Catalog)

  7. Requirements • Technical Requirements • Must be capable withstanding a force, 734 N • Must weigh 15% less than the current design • Must not exceed the allowable budget of $1500. • Must be compatible with ISR 4-piston calipers (22-045) and Tilton 77 Series Master Cylinders. • Must include a method of attaching a data acquisition device (trigger wheel) to monitor testing.

  8. Requirements Cont. • Performance • Must perform basic braking maneuvers and tests • Must be compatible with the 2014 hubs and uprights (specifications). • Must be able to withstand multiple testing trials and driving runs • Must be able to be installed by member of the design team andFormula SAE team. • Must not affect the performance of the car negatively • Must optimize the performance of the vehicles braking system

  9. Requirements Cont. • Scheduling Requirements • Must not be critical to the completion of the car • Must be completed by the end of the design class • Miscellaneous Requirements • Must ensure the safety of the driver and persons in the surrounding area during operation • Must conform to all the rules and regulations of the MECH 4010 design project • Must conform to the rules and regulations set out by the Formula SAE organization

  10. Resources • Facilities • Formula SAE Shop • Machine Shop • Vendor Machine Shops? • Testing • Budget

  11. Testing • Weight and Dimensional Measurements • Stop Test (60 km/hr.) (Dalhousie Formula SAE)

  12. Testing • Theoretical and Computational Analysis • SolidWorks • MATLAB • Sacrificial Testing • Fatigue • Maximum Capability

  13. Schedule for The Semester

  14. Short Term Schedule

  15. Discussion/Questions

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