Improved Thermal Transport for Helical Brake System Group Members: Jim Cloer Matt Evonuk Arek Gazdowicz Dirk Tarman Industry Sponsor Braking Technologies Faculty Advisor Dr. David Sailor Senior Capstone Spring 2005

 Improved clamping force to actuation force ratio  Improved wear characteristics  Equal pad pressure over entire rotor The HeliCal TM Brake Caliper

Design a new housing for the helical brake design that has improved heat dissipation and is able to withstand the mechanical stresses placed upon it Design a new housing for the helical brake design that has improved heat dissipation and is able to withstand the mechanical stresses placed upon it Problem Statement

Design Goals  New housing Can be incorporated into assemblyCan be incorporated into assembly Reduce material usageReduce material usage 400% Increase in heat flux400% Increase in heat flux Reduce the chance of thermal failureReduce the chance of thermal failure 2 safety factor2 safety factor

Chosen Geometry  Concentric vanes Fewer stress concentrationsFewer stress concentrations Less materialLess material Ease of manufactureEase of manufacture Low costLow cost

Testing  Options - Custom built test stand - Custom built test stand - Baja test stand - Baja test stand - Place on racing kart - Place on racing kart - Hot plate - Hot plate

Stress Verification

Thermal Verification

Thermal Result

Final Prototype

Results  Safety factor greater than 2  300% increase in heat flux  Adaptable to current design  Uniform heat flux distribution  Simplified assembly