Download - 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 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
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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 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
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Project Plan Finalizing Design
PatternMaterial Selection
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Questions?