Design And Fabricate A Brake System And Mechanism

Aiman Arrif, Ahamad Tarmizi (2012) Design And Fabricate A Brake System And Mechanism. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

Brake is one of crucial components in almost every vehicle. The need of brake performances is much based on what kind of applications or transportations that particular vehicle is meant to be. Racing car or motorcycle brakes are often made with different kind of material and different characteristics compared to conventional vehicle brakes. Formula Varsity (FV) car that being built has no motor on it yet, so, the brake design is made based on the weight and reference speed targeted on that car. Based on the result of surveys, designing House of Quality methods is used to determine crucial factors of the brake characteristic to be carried out on further designing method using CAD software. The design of the brake disc rotor is decided to be using conventional Perodua Kancil‟s disc brake with some customization made on it such as lathe to flatten it and drilling to match the mounting holes on it. Moreover, a pedal box assemble is being designed using CATIA V5 software with two designs and choosing one of those designs using design scoring method which is Weighted Decision Method. The design „B‟ is chosen. Some calculation is being made to determine any crucial parameter such as clamping force, which is 607.95N per disc and the torque required to stopping the car per disc brake is 741Nm. The analysis is done by using ANSYS software for both disc brake and pedal box assembly. For disc brake analysis, the clamping force is 700N and 789.34 Nm of torque acted on it. The result shows 0.00048699mm of deformation, 11.211Mpa of Von-Misses stress, 6.4637Mpa of shear stress along the disc neck and the safety factor turn out to be more than enough to withstand the clamping force which is more than 10 safety factor based on the software results. For pedal box analysis, there are two sections of force acting and the other parts are fixed. Section A is put 100N of force and section B is 300N of force. The bearing is fixed. The results are 0.070922mm of deformation on the end region of pedal, 33.269Mpa of Von- Misses, 5.8817Mpa of shear stress and the safety factor is shown minimum of 2.591. Based on the results, it shows that both designed part and assembly is meet all the requirements based on the calculations.

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