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Improved Thermal Transport for Helical Brake System

Improved Thermal Transport for Helical Brake System. Group Members: Jim Cloer Matt Evonuk Arek Gazdowicz Dirk Tarman. Industry Sponsor Braking Technologies. Faculty Advisor Dr. David Sailor. Senior Capstone Spring 2005. The HeliCal TM Brake Caliper.

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Improved Thermal Transport for Helical Brake System

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  1. Improved Thermal Transport for Helical Brake System Group Members: Jim Cloer Matt Evonuk Arek Gazdowicz Dirk Tarman Industry Sponsor Braking Technologies Faculty Advisor Dr. David Sailor Senior Capstone Spring 2005

  2. The HeliCalTM Brake Caliper • Improved clamping force to actuation force ratio • Improved wear characteristics • Equal pad pressure over entire rotor

  3. Problem Statement Design a new housing for the helical brake design that has improved heat dissipation and is able to withstand the mechanical stresses placed upon it

  4. Design Goals • New housing • Can be incorporated into assembly • Reduce material usage • 400% Increase in heat flux • Reduce the chance of thermal failure • 2 safety factor

  5. Chosen Geometry • Concentric vanes • Fewer stress concentrations • Less material • Ease of manufacture • Low cost

  6. Testing • Options - Custom built test stand - Baja test stand - Place on racing kart - Hot plate

  7. Stress Verification

  8. Thermal Verification

  9. Thermal Result

  10. Final Prototype

  11. Results • Safety factor greater than 2 • 300% increase in heat flux • Adaptable to current design • Uniform heat flux distribution • Simplified assembly

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