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Design of a Disc Brake

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Conclusion. With this project we achieved a safe, durable and viable design for a rotor component in a disc brake system taking in consideration the forces exerted ... – PowerPoint PPT presentation

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Title: Design of a Disc Brake


1
Design of a Disc Brake
  • Tania M. Ortiz Menéndez
  • Liza M. Cardona Gonzalez
  • Ramon Torres

2
Objectives
  • Design of the rotor component for a disc brake
    system using load analysis, stress analysis and
    fracture analysis system approach.

3
Description
  • Single disc brake component from a brake system
    compound of a master cylinder, a four piston
    caliper, two brake pads and the rotor.
  • It is supposed to produce a torsion from an input
    driver force of 100 lb.

4
How a Brake System Works
5
Mechanical Design
6
Mechanical Design
  • Pedal force 600 lb
  • Master Cylinder 1559.4 psi
  • Caliper Force 78367.3 lb
  • Pads Force 35265.3 lb
  • Rotor Torque 437289.8
  • t 409.97 psi

7
Material Selection
  • Gray Cast Iron wear resistant, hard, good heat
    absorption and dissipation.
  • Sut 40000 psi
  • Suc 150000 psi

8
Mechanical design
  • Kt 2.5 (assumed)
  • t(corrected) 1024.9 psi
  • Static Fracture Analysis (Internal Friction
    Theory)
  • s 1 1024.9 psi, s3 -1024.9 psi
  • n 30.81

9
Mechanical Design
  • Dynamic Fracture Analysis
  • Se 16000 psi
  • Ksurf 1.016
  • Ksize 0.7296
  • Kload 0.59
  • Ktemp 1
  • Krel (99.9)0.814
  • Se 5695 psi

10
Mechanical Design
  • q 0.8 (assumed)
  • Kf 2.2
  • Ta 437289.8 lb
  • ta(corr) 901.934 psi
  • s1 901.94 psi, s3 -901.93 psi
  • Tm 218644.9 lb
  • tm(corr) 450.98 psi
  • s1 450.98 psi, s3 -450.98

11
Mechanical Design
  • Modified-Goodman
  • nf 5.896

12
Mechanical Design
  • Tm 218644.9 lb
  • tm(corr) 450.98 psi
  • s1 450.98 psi, s3 -450.98 psi
  • nf 5.896 (Goddman)
  • Endurance Limit
  • N 99.2 x 107

13
Conclusion
  • With this project we achieved a safe, durable and
    viable design for a rotor component in a disc
    brake system taking in consideration the forces
    exerted for all the components in the brake
    system. In our fracture analysis for the static
    and the dynamic approach we found that our safety
    factor numbers are elevated. With this we
    demonstrate that disc brakes do not fracture.
    That is because the force exerted in the disc is
    a compressive force. Thats why the materials
    used for the manufacturing of brake disc are
    brittle. Also for that reason we calculate a big
    endurance limit.

14
Questions
  • ?
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