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 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.

How a Brake System Works

Mechanical Design

Pedal force = 600 lb Master Cylinder = psi Caliper Force = lb Pads Force = lb Rotor Torque = τ = psi

Material Selection Gray Cast Iron: wear resistant, hard, good heat absorption and dissipation. Sut = psi Suc = psi

Mechanical design Kt = 2.5 (assumed) τ(corrected) = psi Static Fracture Analysis (Internal Friction Theory) σ 1 = psi, σ3 = psi n = 30.81

Mechanical Design Dynamic Fracture Analysis Se’ = psi Ksurf = Ksize = Kload = 0.59 Ktemp = 1 Krel (99.9%)=0.814 Se = 5695 psi

Mechanical Design q = 0.8 (assumed) Kf = 2.2 Ta = lb τa(corr) = psi σ1 = psi, σ3 = psi Tm = lb τm(corr) = psi σ1 = psi, σ3 =

Mechanical Design Modified-Goodman nf = 5.896

Mechanical Design Tm = lb τm(corr) = psi σ1 = psi, σ3 = psi nf = (Goddman) Endurance Limit N = 99.2 x 10 7

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.

Questions ?