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 #2Megan TunneyAlex BurgessKarim ShalohHan Ou Xu

Team Advisor: Dr. Chuang

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Agenda Background Scope Requirements Resources Testing Schedule

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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 Types

VentilatedSlottedDrilled

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3dcadbrowser.com

lmfvauxhall.co.uk

endless-sphere.com

Background Floating Disc

BrakeLateral Degree

of FreedomBetter CanteringRoom for

Expansion (no warping)

Isolates Vibration

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(eliseparts.com)

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)

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Requirements Technical Requirements

Must be capable withstanding a force, 734 NMust weigh 15% less than the current designMust 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.

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Requirements Cont. Performance

Must perform basic braking maneuvers and testsMust be compatible with the 2014 hubs and uprights

(specifications).Must be able to withstand multiple testing trials and

driving runsMust be able to be installed by member of the design

team and Formula SAE team. Must not affect the performance of the car negativelyMust optimize the performance of the vehicles

braking system

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Requirements Cont. Scheduling Requirements

Must not be critical to the completion of the carMust be completed by the end of the design class

Miscellaneous RequirementsMust ensure the safety of the driver and persons in

the surrounding area during operationMust conform to all the rules and regulations of the

MECH 4010 design projectMust conform to the rules and regulations set out by

the Formula SAE organization

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Resources

FacilitiesFormula SAE ShopMachine ShopVendor Machine Shops?

Testing Budget

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Testing Weight and Dimensional Measurements Stop Test (60 km/hr.)

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(Dalhousie Formula SAE)

Testing Theoretical and Computational Analysis

SolidWorksMATLAB

Sacrificial TestingFatigueMaximum Capability

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Schedule for The Semester

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1 Week• Conceptual Design Report

3 Weeks

• Embodiment Design Report

4 Weeks

• Interim Presentations

5 Weeks

• Fall Design Report

Short Term Schedule

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Obtaining Testing Data of Current Design

Analysis of Potential Designs

Conceptual Designs

Discussion/Questions

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