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Design and Analysis of Modular Caliper Assembly

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Design and Analysis of Modular Caliper Assembly DESIGN AND ANALYSIS OF MODULAR CALIPER ASSEMBLY A Thesis by Nikhil Pratap Wagh Bachelor of Engineering, Shivaji University, 2000. Submitted to the College of Engineering and the faculty of the Graduate School of Wichita State University in partial fulfillment of the requirements for the degree of Master of Science December 2005 DESIGN AND ANALYSIS OF MODULAR BRAKE CALIPER ASSEMBLY I have examined the final copy of this thesis for form and content and recommend that it to be accepted in partial fulfillment of the requirements for the degree of Master of Science, with a major in Mechanical Engineering. ____________________________________ Dr. George. E. Talia, Committee Chair We have read this thesis and recommend its acceptance: ____________________________________ Dr. Behnam Bahr, Committee Member ____________________________________ Dr. Krishna Krishnan, Committee Member ii DEDICATION This work is dedicated to My Parents For supporting my vision and help me turning it into reality one day iii ACKNOWLEDGMENTS Completing this thesis although was a challenge for me, would not have endeavored without the support, inspiration, encouragements and contribution of many entities. First of all, I would like to take this opportunity to express my profound thanks to my advisor Dr. George E. Talia for his excellent support during my academic tenure at Wichita State University. I would also like to express my gratitude to Dr. Behnam Bahr and Dr. Krishna K. Krishnan for being my thesis committee members. I would like to thank all my friends for their support and wishes. Last but not least I would like to express my gratefulness to my parents who gave me constant encouragement and inspiration throughout my life to achieve my goals. iv ABSTRACT The following work studies a conceptual design of a disc brake system. Disc brakes offer higher performance braking, simpler design, lighter weight, and better resistance to water interference than drum brakes. The aim of this conceptual design was to increase the strength of the caliper, without increasing the weight of the caliper by a large amount and reducing the thermal deformation at high operating temperatures. Since titanium is difficult to machine the mono block design of conventional machined caliper was not used in this work but an attempt was made to built a brake caliper with different parts and assembled together to make a single unit. Also titanium parts used were machined from plates with no complicated shapes to save on machining costs in future. Since titanium has higher mass density care was taken while designing the new brake system to keep the weight increase to minimum. The existing brake caliper was analyzed for given load conditions with new material suggested. The results were studied for displacements and stresses along with thermal effects. The new modular caliper was analyzed for pressure and tangential loads and the results were studied for displacements/deformation and stresses with temperature effects. v TABLE OF CONTENTS Chapter Page 1. INTRODUCTION ...................................................................................................1 1.1 Background..................................................................................................1 1.2 Vehicle Brake system ..................................................................................2 1.3 Disc Brake Piston Arrangement...................................................................7 1.4 Disc Brake Rotors........................................................................................8 1.5 Objective......................................................................................................8 2. LITERATURE REVIEW......................................................................................11 2.1 Existing Brake Caliper...............................................................................11 2.2 Material Selection for Brake Caliper .........................................................12 2.3 Brake Pad Material ....................................................................................13 2.4 Thermal Study of Brake Caliper................................................................14 2.5 Structural Analysis of Conventional Brake Caliper using Al 6061...........16 3. ANALYSIS OF CONVENTIONAL CALIPER ...................................................18 3.1 Structural Analysis of Conventional Brake Caliper...................................18 3.2 Structural Analysis of Conventional Caliper with Thermal Effects ..........25 4. MODULAR CALIPER DESIGN..........................................................................29 4.1 Design Concept..........................................................................................29 4.2 Modular Caliper Assembly........................................................................33 5. ANALYSIS OF NEW MODULAR CALIPER.....................................................39 5.1 Thermal Study of Modular Brake Caliper .................................................39 5.2 Structural Study of Modular Brake Caliper...............................................43 5.3 Structural Analysis of Modular Brake Caliper ..........................................47 5.4 Structural Analysis of Modular Caliper with Thermal Effects..................51 6. CONCLUSIONS AND RECOMMENDATIONS ................................................55 6.1 Discussion and Conclusion........................................................................55 6.2 Recommendations......................................................................................56 vi LIST OF REFRENCES .....................................................................................................57 APPENDIXES ...................................................................................................................59 APPENDIX A: ALGOR FINITE ELEMENT ANALYSIS REPORT..............................60 APPENDIX B-1: DETAILED DRAWING OF ALUMINUM BLOCK ..........................68 APPENDIX B-2: DETAILED DRAWING OF EXTERNAL PLATE.............................69 APPENDIX B-3: DETAILED DRAWING OF STOPPER ..............................................70 APPENDIX B-4: DETAILED DRAWING OF PAD PLATE..........................................71 APPENDIX B-5: DETAILED DRAWING OF PISTON .................................................72 APPENDIX B-6: DETAILED DRAWING OF ROTOR..................................................73 vii LIST OF TABLES Table Page 3-1 Physical properties of Al 2219...............................................................................20 5-1 Physical Properties of Aluminum and Titanium ...................................................46 6-1 Displacements/deformation in Calipers.................................................................56 viii LIST OF FIGURES Figure Page 1-1 Vehicle brake system ...............................................................................................2 1-2 Drum brake system ..................................................................................................3 1-3 Disc brake system ....................................................................................................4 1-4 Floating caliper design.............................................................................................5 1-5 Fixed caliper design .................................................................................................6 1-6 Piston retraction adjustment.....................................................................................7 1-6 Heat generated during braking.................................................................................8 1-7 Internal vanes in the rotor ........................................................................................9 1-8 Vented disc brake rotor..........................................................................................10 2-1 Conventional Brake Caliper...................................................................................11 2-2 Temperature Isolation Using Ti Inserts .................................................................15 2-3 Temperature distribution in existing caliper..........................................................16 2-4 Stress in existing caliper with Al 6061 material ....................................................17 2-5 Displacement in Z-direction in existing caliper with Al 6061 material.................17 3-1 Conventional caliper model used for FEA.............................................................18 3- 2 Conventional caliper loading and trailing edge .....................................................19 3- 3 Model of Conventional Caliper with loads and constraints...................................20 3- 4 Stress distribution in conventional caliper.............................................................21 3- 5 Displacement in conventional caliper....................................................................22 ix 3- 6 Displacement in Z direction in conventional caliper .............................................23 3- 7 Displacement in X direction in conventional caliper.............................................24 3- 8 Stresses in conventional caliper including thermal................................................25 3- 9 Displacement in conventional caliper including thermal.......................................26 3- 10 Displacement in Z direction conventional caliper including thermal....................27 3- 11 Displacement
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