1. 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. 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

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) τ(corrected) = 1024.9 psi Static Fracture Analysis (Internal Friction Theory) σ 1 = 1024.9 psi, σ3 = -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 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

11. Mechanical Design Modified-Goodman nf = 5.896

12. 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 10 7

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. That’s why the materials used for the manufacturing of brake disc are brittle. Also for that reason we calculate a big endurance limit.

14. Questions ?