1. 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

2. Agenda  Background  Scope  Requirements  Resources  Testing  Schedule 2 (Dalhousie Formula SAE)

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

4. Background  Types Ventilated Slotted Drilled 4 3dcadbrowser.com lmfvauxhall.co.uk endless-sphere.com

5. Background  Floating Disc Brake Lateral Degree of Freedom Better Cantering Room for Expansion (no warping) Isolates Vibration 5 (eliseparts.com)

6. 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

7. 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

8. 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

9. 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

10. Resources  Facilities Formula SAE Shop Machine Shop Vendor Machine Shops?  Testing  Budget 10

11. Testing  Weight and Dimensional Measurements  Stop Test (60 km/hr.) 11 (Dalhousie Formula SAE)

12. Testing  Theoretical and Computational Analysis SolidWorks MATLAB  Sacrificial Testing Fatigue Maximum Capability 12

13. Schedule for The Semester 13 1 Week Conceptual Design Report 3 Weeks Embodiment Design Report 4 Weeks Interim Presentations 5 Weeks Fall Design Report

14. Short Term Schedule 14 Obtaining Testing Data of Current Design Analysis of Potential Designs Conceptual Designs

15. Discussion/Questions 15