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Performance	
  Brake	
  Kit:	
  	
  
MAE	
  489	
  Final	
  Presenta:on	
  
Ian	
  Kubik	
  
Tyler	
  Lemonds	
  
Aus:n	
 ...
Contents:	
  	
  
•  Project	
  Overview:	
  

o  Problem	
  Statement	
  
o  Summary	
  of	
  Components	
  

•  This	
  ...
Problem	
  Statement
	
  
The	
   OEM	
   braking	
   equipment	
   on	
   the	
   Honda	
   S2000	
   is	
   more	
   tha...
Problem	
  Solu:on
	
  
•  Achieved	
  weight/performance	
  goals	
  through	
  
materials,	
  increased	
  brake	
  torq...
Key	
  design	
  aspects
	
  
•  Modularity	
  
•  Mul:-­‐func:on	
  bracket	
  
•  Stock	
  hardware	
  
Summary	
  of	
  Components	
  
•  Calipers:	
  Fully	
  designed,	
  tested,	
  
and	
  built	
  
•  Three	
  “half”	
  p...
Summary	
  of	
  Components	
  
•  Brackets:	
  Designed,	
  tested,	
  and	
  built.	
  
Summary	
  of	
  Components	
  
•  Pistons	
  and	
  rotor	
  hats:	
  Designed,	
  tested,	
  built.	
  
(but	
  somewhat...
Summary	
  of	
  Components	
  
•  Bolts	
  and	
  studs:	
  tested	
  to	
  ensure	
  strength,	
  and	
  
purchased.	
  
Summary	
  of	
  Components	
  
•  Dowel	
  pins,	
  screws,	
  nuts,	
  seals,	
  valves,	
  brake	
  
pads:	
  purchased...
Summary	
  of	
  Components	
  
•  Rotor:	
  somewhat	
  tested,	
  bought.	
  
•  Unable	
  to	
  build	
  due	
  to	
  m...
Summary	
  of	
  Components	
  
•  Small	
  parts	
  we	
  built	
  but	
  didn’t	
  really	
  “design”/
test:	
  the	
  c...
nd	
  Semester	
  Plan	
  
2

•  Knew	
  our	
  project	
  would	
  be	
  MFG-­‐heavy,	
  so	
  we	
  
planned	
  to	
  st...
Manufacturing	
  
•  Required	
  custom	
  tooling	
  to	
  be	
  designed	
  and	
  
ground.	
  
•  Custom	
  fixturing	
 ...
Manufacturing	
  
•  CNC	
  mill	
  programmed	
  and	
  operated	
  by	
  Ian:	
  
–  Brackets,	
  calipers,	
  &	
  roto...
Manufacturing	
  
•  Other	
  simple	
  opera:ons	
  performed	
  on	
  lathe	
  
(manual	
  and	
  CNC)	
  and	
  manual	...
Manufacturing:	
  Some	
  Issues,	
  None	
  
Major	
  
•  Material	
  re-­‐welded	
  aber	
  a	
  tool	
  was	
  
program...
Manufacturing:	
  Some	
  Issues,	
  None	
  
Major	
  
•  One	
  pin	
  hole	
  messed	
  up,	
  but	
  was	
  repaired	
...
Design	
  Changes	
  
•  Many	
  updates	
  since	
  last	
  semester,	
  mostly	
  
small.	
  
Design	
  Changes	
  
•  Materials	
  
–  Bracket	
  slider	
  (changed	
  to	
  Al-­‐6061)	
  
–  Pistons	
  (different	
 ...
Design	
  Changes	
  
•  Many	
  updates	
  to	
  the	
  fluid	
  lines	
  &	
  valves:	
  
Design	
  Changes	
  
•  Other	
  small	
  updates	
  to	
  
calipers,	
  brackets,	
  
pistons.	
  	
  	
  
Design	
  Changes	
  
•  Biggest	
  change	
  was	
  due	
  to	
  a	
  
measuring	
  error	
  that	
  required	
  
the	
  ...
Structural	
  FEA	
  Re-­‐test	
  
•  Wanted	
  to	
  re-­‐test	
  our	
  FEA	
  results	
  from	
  the	
  
previous	
  se...
Rotor	
  Design
	
  
•  Last	
  semester,	
  began	
  rotor	
  design	
  with	
  ANSYS	
  CFX.	
  	
  	
  
•  Planned	
  t...
Prototype	
  Tes:ng:	
  Approach	
  
•  Standardize	
  as	
  much	
  as	
  possible	
  
•  Determine	
  60-­‐0	
  braking	...
Prototype	
  Tes:ng:	
  Results	
  
•  32	
  total	
  runs	
  among	
  the	
  3	
  setups.	
  	
  	
  
•  ANOVA	
  test	
 ...
Prototype	
  Tes:ng:	
  Difficul:es	
  
•  ABS	
  ac:va:ng	
  	
  
–  Stock	
  rear	
  system	
  and	
  pads	
  
–  Less	
  ...
Prototype	
  Tes:ng:	
  Summary	
  
•  Some	
  results	
  (floa:ng)	
  show	
  our	
  system	
  is	
  
significantly	
  beoe...
Design	
  Valida:on:	
  
•  Performance	
  
–  Clear	
  success	
  for	
  floa:ng,	
  fixed	
  needs	
  more	
  
tes:ng	
  
...
Design	
  Valida:on:	
  Cost	
  
•  How	
  much	
  would	
  the	
  kit	
  cost	
  if	
  we	
  sold	
  it?	
  
–  $75.00	
 ...
Budget	
  Results:	
  
•  Dollars:	
  $819.46	
  spent	
  from	
  $800	
  budget	
  	
  
–  Materials:	
  ~$420	
  
–  Par...
“Produc:on”	
  Design	
  Changes:	
  
•  Larger	
  rotor	
  	
  
–  Backing	
  plate	
  clearance	
  
–  Increased	
  stud...
“Produc:on”	
  Design	
  Changes:	
  
•  Con:nued	
  minor	
  
changes	
  to	
  
mul:ple	
  features	
  
“Produc:on”	
  Design	
  Changes
	
  
•  Add	
  a	
  feature	
  to	
  make	
  
floa:ng	
  assembly	
  easier	
  
to	
  blee...
Conclusion:	
  Areas	
  of	
  Success	
  
•  Overall	
  everything	
  turned	
  out	
  
preoy	
  well	
  in	
  terms	
  of...
Conclusion:	
  Areas	
  for	
  Improvement	
  
•  Insufficient	
  :me/	
  funds	
  to	
  test	
  system	
  with	
  
fully	
 ...
Conclusions:	
  Acknowledgements	
  
•  Thank	
  you	
  to	
  Baer	
  Inc	
  for	
  the	
  design	
  feedback	
  
and	
  a...
Ques:ons?	
  
•  Feel	
  free	
  to	
  come	
  up	
  and	
  touch	
  stuff?	
  
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Final Presentation - Senior Design Project

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Final presentation/design review of senior design project for Mechanical Engineering undergraduate degree at Arizona State University.

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Final Presentation - Senior Design Project

  1. 1. Performance  Brake  Kit:     MAE  489  Final  Presenta:on   Ian  Kubik   Tyler  Lemonds   Aus:n  Malm   Lucas  Thompson   2013  July  11  
  2. 2. Contents:     •  Project  Overview:   o  Problem  Statement   o  Summary  of  Components   •  This  semester’s  work:   o  o  o  o  Manufacturing   Design  changes   Re-­‐analyze  ANSYS  results     Prototype  Tes:ng   •  Project  Deliverables:   o  Budgets   o  Valida:on  of  Goal  Parameters   •  Conclusions:   o  o  o  o  Changes  to  “produc:on”  design   Areas  of  success   Areas  for  improvement   Acknowledgements   •  Ques:ons  
  3. 3. Problem  Statement   The   OEM   braking   equipment   on   the   Honda   S2000   is   more   than   adequate   for   regular   street   use;   however,   when   subjected   to   the   demands  of  performance  driving  the  system’s  braking  capacity  does   not  suffice.   The   “weekend”   car   enthusiast   that   aspires   to   increase   braking   performance   is   forced   to   upgrade   his   wheels,   brackets,   and   oben   rotor   as   well   in   order   to   sufficiently   increase   the   vehicle’s   braking   performance.   •  Our  goals  for  func:onal  valida:on:   –  –  –  –  –  Decrease  system  weight.   Maintain  proper  balance  between  front/rear  brakes.   Increase  performance,  specifically  stopping  distance  and  heat  dissipa:on.   Low  cost  compared  to  other  op:ons  on  the  market.       Fit  original  equipment  manufacturer  components  
  4. 4. Problem  Solu:on   •  Achieved  weight/performance  goals  through   materials,  increased  brake  torque,  FEA   analysis.     •  Modular  configura:on  for  best  performance   while  mee:ng  cost  requirements   –  Fixed:  performance   –  Floa:ng:  cost/  OEM  fitment   •  Novel  method  of  “upgrading”  that  saves   money  and  material.      
  5. 5. Key  design  aspects   •  Modularity   •  Mul:-­‐func:on  bracket   •  Stock  hardware  
  6. 6. Summary  of  Components   •  Calipers:  Fully  designed,  tested,   and  built   •  Three  “half”  pieces  with  leb  and   right  sides.  
  7. 7. Summary  of  Components   •  Brackets:  Designed,  tested,  and  built.  
  8. 8. Summary  of  Components   •  Pistons  and  rotor  hats:  Designed,  tested,  built.   (but  somewhat  simpler  components)   •     8  pistons  of  4  different  sizes;  2  rotor  hats  
  9. 9. Summary  of  Components   •  Bolts  and  studs:  tested  to  ensure  strength,  and   purchased.  
  10. 10. Summary  of  Components   •  Dowel  pins,  screws,  nuts,  seals,  valves,  brake   pads:  purchased.  (Brake  pad  p.f.c  data  used  in   other  tests)    
  11. 11. Summary  of  Components   •  Rotor:  somewhat  tested,  bought.   •  Unable  to  build  due  to  manufacturing  process   (cas:ng).    
  12. 12. Summary  of  Components   •  Small  parts  we  built  but  didn’t  really  “design”/ test:  the  covers  for  the  brake  pad  reten:on   screws  &  spacers  for  the  bracket    
  13. 13. nd  Semester  Plan   2 •  Knew  our  project  would  be  MFG-­‐heavy,  so  we   planned  to  start  immediately.   •  Design  changes  made  throughout  the  MFG   process,  for  reasons  of  MFG-­‐ability,  size   constraints,  general  performance.     •  Prototype  tes:ng  towards  the  end  of  the   semester  (but  as  soon  as  we  could):  needed  to   test  stock,  fixed,  and  floa:ng  configura:ons.   •  Perform  new  solid  model  tests,  to  verify  safety  of   all  design  changes.       •  Renewed  focus  on  keeping  up-­‐to-­‐date  on   paperwork.      
  14. 14. Manufacturing   •  Required  custom  tooling  to  be  designed  and   ground.   •  Custom  fixturing  for  each  opera:on  
  15. 15. Manufacturing   •  CNC  mill  programmed  and  operated  by  Ian:   –  Brackets,  calipers,  &  rotor  hats  
  16. 16. Manufacturing   •  Other  simple  opera:ons  performed  on  lathe   (manual  and  CNC)  and  manual  mill:   –  chamfers  on  rotor  hats  and  brackets   –  pins,  spacers  
  17. 17. Manufacturing:  Some  Issues,  None   Major   •  Material  re-­‐welded  aber  a  tool  was   programmed  incorrectly   • Everything  took   longer  than  expected   (as  usual).      
  18. 18. Manufacturing:  Some  Issues,  None   Major   •  One  pin  hole  messed  up,  but  was  repaired   •  Design  changes  made  to  simplify  the   manufacturing  process.     •  Thru  body  fluid  ports  
  19. 19. Design  Changes   •  Many  updates  since  last  semester,  mostly   small.  
  20. 20. Design  Changes   •  Materials   –  Bracket  slider  (changed  to  Al-­‐6061)   –  Pistons  (different  grade  stainless  steel)   –  Bushings  (bronze  features  added)  
  21. 21. Design  Changes   •  Many  updates  to  the  fluid  lines  &  valves:  
  22. 22. Design  Changes   •  Other  small  updates  to   calipers,  brackets,   pistons.      
  23. 23. Design  Changes   •  Biggest  change  was  due  to  a   measuring  error  that  required   the  rotor  hat  to  be  rebuilt  
  24. 24. Structural  FEA  Re-­‐test   •  Wanted  to  re-­‐test  our  FEA  results  from  the   previous  semester,  aber  incorpora:ng  all   design  changes.     •  Would  refine  tests  based  on  what  we  learned   last  semester.   •  Planned  but  not  completed  due  to  :me.    
  25. 25. Rotor  Design   •  Last  semester,  began  rotor  design  with  ANSYS  CFX.       •  Planned  to  refine  and  connect  numerical  results  to  field  tests   via  recorded  temperatures,  and  to  lab  tests  (mass  flow).   •  Create  improved  model  through  parametric  design  with   numerical  and  field  tests  as  valida:on.         •  Uncompleted  due  to  focus  on  manufacturing.  
  26. 26. Prototype  Tes:ng:  Approach   •  Standardize  as  much  as  possible   •  Determine  60-­‐0  braking  distance  while   monitoring  cri:cal  parameters   –  Temperature   •  Rotor,  caliper,     :re,  road  surface   –  Tire  pressure   •  Same  stretch  of  road   •  Maintain  fuel  level  
  27. 27. Prototype  Tes:ng:  Results   •  32  total  runs  among  the  3  setups.       •  ANOVA  test  for  3-­‐way  inter-­‐comparison.   • P=0.0081 means a sta:s:cally significant result.
  28. 28. Prototype  Tes:ng:  Difficul:es   •  ABS  ac:va:ng     –  Stock  rear  system  and  pads   –  Less  than  ideal  :res  and  sizing   •  Rotor/Pads  fully  bedded  for  ini:al  tests   •  No  way  to  perfectly  standardize  procedure   (stopping  loca:on  and  speed  both  done  by   eye)   •  Nature  of  project  is  difficult  to  get  many  data   points   •  Standardize  bleeding  procedure  
  29. 29. Prototype  Tes:ng:  Summary   •  Some  results  (floa:ng)  show  our  system  is   significantly  beoer.   •  Biggest  difficulty  with  ABS  ac:va:ng   •  Original  goal  was  to  “maintain  balance”   •  Performance  pads  necessary  for  rear  brakes   •  Would  always  be  beoer  if  we  could’ve  done   more.    
  30. 30. Design  Valida:on:   •  Performance   –  Clear  success  for  floa:ng,  fixed  needs  more   tes:ng   •  Weight   –  Lighter  than  stock:  check   •  Cost   –  Modularity  means  significant  savings   –  Cost  details  on  next  page   •  Balance   –  Somewhat  of  a  failure  here   •  Fit  OEM  components   –  Drove  the  design  at  many  points.    A  success   overall.    
  31. 31. Design  Valida:on:  Cost   •  How  much  would  the  kit  cost  if  we  sold  it?   –  $75.00  pads   –  ~$200.00  for  caliper  raw  materials   –  ~$100.00  for  bracket/rotor  hat  materials   –  ~$45.00  for  pistons   –  ~25hrs  machine  :me  (prototyping—produc:on   would  be  much  less)   •  Cost  always  depends  on  produc:on  volume.   •  ASU  machine  shop  tooling  not  perfect.    
  32. 32. Budget  Results:   •  Dollars:  $819.46  spent  from  $800  budget     –  Materials:  ~$420   –  Parts:  ~$256   •  Labor  budget:   –  Who  knows…  
  33. 33. “Produc:on”  Design  Changes:   •  Larger  rotor     –  Backing  plate  clearance   –  Increased  stud   engagement   –  Improved  thermal   –  Aesthe:cs   •  Use  a  common  bolt  size   •  Longer  studs   •  Clearance  for  installa:on   –  socket  
  34. 34. “Produc:on”  Design  Changes:   •  Con:nued  minor   changes  to   mul:ple  features  
  35. 35. “Produc:on”  Design  Changes   •  Add  a  feature  to  make   floa:ng  assembly  easier   to  bleed  (remove  air  from   the  system).    
  36. 36. Conclusion:  Areas  of  Success   •  Overall  everything  turned  out   preoy  well  in  terms  of:   –  Budget   –  Brakes  func:on  correctly   –  Original  design  goals  rela:vely   well  validated   –  Made  updates  for  future     designs.      
  37. 37. Conclusion:  Areas  for  Improvement   •  Insufficient  :me/  funds  to  test  system  with   fully  worn  brake  pads   •  Further  tests  against  other  brake  kits  (both   computa:onal  and  field  tes:ng)   •  Had  to  build  more  parts  than  we  planned  in   the  beginning   •  Always  luck  involved  in  a  class  like  this,  and   ours  was  mostly  good  
  38. 38. Conclusions:  Acknowledgements   •  Thank  you  to  Baer  Inc  for  the  design  feedback   and  access  to  parts.   •  Thank  you  to  Dr.  Middleton  &  Dr.  Squires  for   many  helpful  discussions.   •  And  thanks  to  everyone  who’s  helped  us   through  these  past  few  years  
  39. 39. Ques:ons?   •  Feel  free  to  come  up  and  touch  stuff?  

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