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
1
Agenda








Background
Requirements
Alternative
Concepts
Analysis of
Alternative
Concepts
Engineering
Analysis
Selected Design
Budget
Project Plan
(Dalhousie Formula SAE)
2
Background

Brake System
 Master Cylinder
 Brake Fluid
 Caliper and Rotor
Brake system schematic
(tegger.com)
(Wikipedia-Disc brake)
3
Background

Floating Disc
Brake
 Lateral Degree
of Freedom
 Better Cantering
 Room for
Expansion (no
warping)
 Isolates Vibration
(eliseparts.com)
4
Background

Dalhousie Formula SAE Current Design
 Rotors:
○ Front: 250mm Fully Floating Rotor
○ Rear: 200m Fully Floating Rotor
5
Background

Dalhousie Formula SAE Current Design
 Carrier
○ Designed and Manufactured by the Formula
SAE Team
6
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
7
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.
8
Alternative Concepts

Rotor
Blank
Slotted
Drilled
Drilled and Slotted
9
Alternative Concepts

Carrier
Curved Spoke
Slanted Spoke
Star Spoke
10
Analysis of Alternative Concepts
11
Analysis of Alternative Concepts

Solidworks Simulations
12
Engineering Analysis

Material Stress
 Clamping Force on Rotor
 Rotor and Carrier Material Strength
 Safety Factor
F = ma
F
s=
A
s All
SF =
s Re q
t=
16TDo
p (Do4 - Di4 )
13
Engineering Analysis

Thermal Stress
 Temperature During
Stop Tests
○ 40°C Increase
 Material Heat Transfer
○ Specific Material
Properties
Q = mcp DT
(NETZSCH Thermal Analysis)
14
Engineering Analysis

Solidworks Simulations
15
Selected Design
Rotor
 Carrier
 Buttons

16
Selected Design

Rotor
 Stainless Steel
 Slotted and Drilled
Pattern
 Curved Star
Patterned Spokes
17
Selected Design

Carrier
 Aluminum
 Minimal Extension
from Hub
 Slotted
 Star Spoke Pattern
18
Final Design

Buttons
 Stainless Steel
 Two Pin, Two Plate
Design
 Welded Connection
19
Budget
Quotations
 Sponsorships
 Simplifying Design

 Performance vs. Budget
Company
Product
Quote
Quality 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
20
Budget Break Down
21
Project Plan

Overview
Testing
Current
Design
Final Design
Manufacturing
Mid February
March
End January
Testing Final
Design
March
Theoretical
Pattern
Theoretical
Practical
Materials
Practical
22
Project Plan
Testing
Current
Design
Final Design
Manufacturing
Mid February
March
End January
Testing Final
Design
March
Theoretical
Pattern
Practical
Practical
Materials
Theoretical
23
Project Plan

Testing
 Theoretical
○ Material Stress
○ Heat Transfer
24
Project Plan
Testing
Current
Design
Final Design
Manufacturing
Mid February
March
End January
Testing Final
Design
March
Theoretical
Pattern
Practical
Practical
Materials
Theoretical
25
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
26
Project Plan
Testing
Current
Design
Final Design
Manufacturing
Mid February
March
End January
Testing Final
Design
March
Theoretical
Pattern
Practical
Practical
Materials
Theoretical
27
Project Plan

Finalizing Design
 Pattern
 Material Selection
28
Questions?
29