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

Agenda  Background  Requirements  Alternative Concepts  Analysis of Alternative Concepts  Engineering Analysis  Selected Design  Budget  Project Plan 2 (Dalhousie Formula SAE)

Background  Brake System Master Cylinder Brake Fluid Caliper and Rotor (Wikipedia-Disc brake) Brake system schematic (tegger.com) 3

Background  Floating Disc Brake Lateral Degree of Freedom Better Cantering Room for Expansion (no warping) Isolates Vibration 4 (eliseparts.com)

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 SlottedDrilled and Slotted Drilled 9

Alternative Concepts  Carrier Curved SpokeSlanted SpokeStar 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 13

Engineering Analysis  Thermal Stress Temperature During Stop Tests ○ 40°C Increase Material Heat Transfer ○ Specific Material Properties (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 CompanyProductQuote Quality Machining Services Ltd. Full Brake Rotor Assembly (1) $ Macgregor’s Ltd.Full Brake Rotor Assembly (1) $ Specialty Steel Inc.Brake Rotor (1), Brake Carrier(1) $

Budget Break Down 21

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

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

Project Plan  Testing Theoretical ○ Material Stress ○ Heat Transfer 24

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

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

Project Plan  Finalizing Design Pattern Material Selection 28

Questions? 29