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Design of a Disc Brake. Tania M. Ortiz Menéndez Liza M. Cardona Gonzalez Ramon Torres. Objectives. Design of the rotor component for a disc brake system using load analysis, stress analysis and fracture analysis system approach. . Description.

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design of a disc brake

Design of a Disc Brake

Tania M. Ortiz Menéndez

Liza M. Cardona Gonzalez

Ramon Torres

objectives
Objectives

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

description
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.
mechanical design1
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

τ = 409.97 psi

material selection
Material Selection
  • Gray Cast Iron: wear resistant, hard, good heat absorption and dissipation.
  • Sut = 40000 psi
  • Suc = 150000 psi
mechanical design2
Mechanical design
  • Kt = 2.5 (assumed)
  • τ(corrected) = 1024.9 psi

Static Fracture Analysis (Internal Friction Theory)

  • σ 1 = 1024.9 psi, σ3 = -1024.9 psi
  • n = 30.81
mechanical design3
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
mechanical design4
Mechanical Design
  • q = 0.8 (assumed)
  • Kf = 2.2
  • Ta = 437289.8 lb
  • τa(corr) = 901.934 psi
  • σ1 = 901.94 psi, σ3 = -901.93 psi
  • Tm = 218644.9 lb
  • τm(corr) = 450.98 psi
  • σ1 = 450.98 psi, σ3 = -450.98
mechanical design5
Mechanical Design
  • Modified-Goodman

nf = 5.896

mechanical design6
Mechanical Design
  • Tm = 218644.9 lb
  • τm(corr) = 450.98 psi
  • σ1 = 450.98 psi, σ3 = -450.98 psi
  • nf = 5.896 (Goddman)

Endurance Limit

  • N = 99.2 x 107
conclusion
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. That’s why the materials used for the manufacturing of brake disc are brittle. Also for that reason we calculate a big endurance limit.