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
1
Agenda
Background
 Scope
 Requirements
 Resources
 Testing
 Schedule

(Dalhousie Formula SAE)
2
Background

Brake System
 Master Cylinder
 Brake Fluid
 Caliper and Rotor
Brake system schematic
(tegger.com)
(Wikipedia-Disc brake)
3
Background

Types
 Ventilated
 Slotted
 Drilled
3dcadbrowser.com
endless-sphere.com
lmfvauxhall.co.uk
4
Background

Floating Disc
Brake
 Lateral Degree
of Freedom
 Better Cantering
 Room for
Expansion (no
warping)
 Isolates Vibration
(eliseparts.com)
5
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)
6
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.
7
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 and Formula SAE team.
 Must not affect the performance of the car negatively
 Must optimize the performance of the vehicles
braking system
8
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
9
Resources



Facilities
 Formula SAE Shop
 Machine Shop
 Vendor Machine Shops?
Testing
Budget
10
Testing
Weight and Dimensional Measurements
 Stop Test (60 km/hr.)

(Dalhousie Formula SAE)
11
Testing

Theoretical and Computational Analysis
 SolidWorks
 MATLAB

Sacrificial Testing
 Fatigue
 Maximum Capability
12
Schedule for The Semester
1 Week
3 Weeks
4 Weeks
5 Weeks
• Conceptual Design Report
• Embodiment Design Report
• Interim Presentations
• Fall Design Report
13
Short Term Schedule
Obtaining Testing Data
of Current Design
Analysis of Potential
Designs
Conceptual Designs
14
Discussion/Questions
15