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

MECH 4010- Design Project I, Fall 2013 Formula SAE Brake Rotor Optimization Interim Presentation November 28, 2013. Team #2 Alex Burgess Karim Shaloh Megan Tunney HanOu Xu Team Advisor: Dr. Chuang. Agenda. Background Requirements Alternative Concepts

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

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  1. MECH 4010- Design Project I, Fall 2013 Formula SAE Brake Rotor Optimization Interim Presentation November 28, 2013 Team #2 Alex Burgess Karim Shaloh Megan Tunney HanOu Xu Team Advisor: Dr. Chuang

  2. Agenda • Background • Requirements • Alternative Concepts • Analysis of Alternative Concepts • Engineering Analysis • Selected Design • Budget • Project Plan (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 • Floating Disc Brake • Lateral Degree of Freedom • Better Cantering • Room for Expansion (no warping) • Isolates Vibration (eliseparts.com)

  5. Background • Dalhousie Formula SAE Current Design • Rotors: • Front: 250mm Fully Floating Rotor • Rear: 200m Fully Floating Rotor

  6. Background • Dalhousie Formula SAE Current Design • Carrier • Designed and Manufactured by the Formula SAE Team

  7. 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

  8. 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.

  9. Alternative Concepts • Rotor Blank Drilled Slotted Drilled and Slotted

  10. Alternative Concepts • Carrier Curved Spoke Slanted Spoke Star Spoke

  11. Analysis of Alternative Concepts

  12. Analysis of Alternative Concepts • Solidworks Simulations

  13. Engineering Analysis • Material Stress • Clamping Force on Rotor • Rotor and Carrier Material Strength • Safety Factor

  14. Engineering Analysis • Thermal Stress • Temperature During Stop Tests • 40°C Increase • Material Heat Transfer • Specific Material Properties (NETZSCH Thermal Analysis)

  15. Engineering Analysis • Solidworks Simulations

  16. Selected Design • Rotor • Carrier • Buttons

  17. Selected Design • Rotor • Stainless Steel • Slotted and Drilled Pattern • Curved Star Patterned Spokes

  18. Selected Design • Carrier • Aluminum • Minimal Extension from Hub • Slotted • Star Spoke Pattern

  19. Final Design • Buttons • Stainless Steel • Two Pin, Two Plate Design • Welded Connection

  20. Budget • Quotations • Sponsorships • Simplifying Design • Performance vs. Budget

  21. Budget Break Down

  22. Project Plan • Overview Testing Current Design End January Final Design Mid February Manufacturing March Testing Final Design March Theoretical Pattern Theoretical Practical Practical Materials

  23. Project Plan Testing Current Design End January Final Design Mid February Manufacturing March Testing Final Design March Theoretical Pattern Practical Practical Materials Theoretical

  24. Project Plan • Testing • Theoretical • Material Stress • Heat Transfer

  25. Project Plan Testing Current Design End January Final Design Mid February Manufacturing March Testing Final Design March Theoretical Pattern Practical Practical Materials Theoretical

  26. Project Plan • MoTEC Data Acquisition Device • Stop Test • Vehicle on Stocks • Replace FSAE Wheel with Flywheel • Mimic Rolling Inertia • Measure Temperature • Brake Locking • Multiple braking Heat Build-up

  27. Project Plan Testing Current Design End January Final Design Mid February Manufacturing March Testing Final Design March Theoretical Pattern Practical Practical Materials Theoretical

  28. Project Plan • Finalizing Design • Pattern • Material Selection

  29. Questions?

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