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Rotor Design for Disc Brake System

This document describes the design of a rotor component for a disc brake system. It details the mechanical design process, which included determining the input forces from the brake pedal and caliper, and using these values to calculate the torque and stresses on the rotor. A gray cast iron material was selected for its wear and heat resistance. Fracture analysis using internal friction theory and the Modified-Goodman method found safety factors above 1, indicating the design would not fracture. The conclusion states the design achieves a safe and durable rotor that can withstand the compressive forces of the brake system without fracturing.

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Jake Polo Santiago
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16 views14 pages

Rotor Design for Disc Brake System

This document describes the design of a rotor component for a disc brake system. It details the mechanical design process, which included determining the input forces from the brake pedal and caliper, and using these values to calculate the torque and stresses on the rotor. A gray cast iron material was selected for its wear and heat resistance. Fracture analysis using internal friction theory and the Modified-Goodman method found safety factors above 1, indicating the design would not fracture. The conclusion states the design achieves a safe and durable rotor that can withstand the compressive forces of the brake system without fracturing.

Uploaded by

Jake Polo Santiago
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd

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
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
 Gray Cast Iron: wear resistant, hard, good heat
absorption and dissipation.
 Sut = 40000 psi
 Suc = 150000 psi
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 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 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 Design
 Modified-Goodman
nf = 5.896
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
 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

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