Design Data Report

Design Data Report

Sub Team Name: Vehicle Dynamics System Name: Brakes Members Name: Ahmed Nasser, Michael Geroge, Mohamed Moussa Overall Specifications: All System’s Materials Used

Performance targets System’s Shape Description Mounting Method Number of Parts

Manufacturing Processes for each part System’s overall Weight Percentage of Weight Reduction

For Master Cylinder , Calipers , Rotors : As purchased Bias bar : for bar & swivel : Steel AISI 4130 for trunion : Aluminum 6061 for sleeve : Aluminum 6061 Locking of 4 wheels of the vehicle , Front axle first , Stopping Distance 25 m from 60 Km/hr in 3 sec 2 Master cylinders and 4 calipers joined together with hoses and fittings Master cylinders mounted on the pedal box and the calipers mounted on the brackets 19 parts consists of two masters cylinders and four calipers and four rotors , 6 hoses & 2 lines , Brake over travel switch , not including pedal box and caliper fixation N/A N/A N/A

Ain Shams University Racing Team’17 _Formula Student

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Design Data Report

Ain Shams University Racing Team’17 _Formula Student

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Design Data Report Figure 1: System CAD

Brakes lines : we decided to draw the lines of the braking system in order to avoid any future problems that might be happen due to improper placement of the braking lines .

Ain Shams University Racing Team’17 _Formula Student

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Design Data Report

Bias bar :Bias bar or the balance bar is responsible for the distribution of the Pedal Force using the Balance Bar ratio which can be adjusted,the material used for manufactring

Ain Shams University Racing Team’17 _Formula Student

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Design Data Report

Trunion is the main part of the bias bar which connects all the parts together and with the Pedal box

The “ bar “ is the part which is responsible for the bias ratio

This joint connect between the bias bar rod and the master cylinder rod also it can take different angles as it’s flexible to move with the aid of ball joint

Swivel is the connecting part between bias bar and trunion

Ain Shams University Racing Team’17 _Formula Student

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Design Data Report

Stress analysis of Bias bar : Stress analysis for the 70-30 bar

Material : Steel AISI 4130 Max Stress : 153.2 Mpa Displacement : 0.087 mm Min Safety Factor : 1.8

Ain Shams University Racing Team’17 _Formula Student

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Design Data Report

Stress analysis for 50-50 bar Material : Steel AISI 4130 Max Stress : 209 MPa Displacement : 0.094 mm Min Safety Factor : 1.32

Ain Shams University Racing Team’17 _Formula Student

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Design Data Report

Stress analysis for the swivel

Material : Steel AISI 4130 Max Stress : 204 Mpa Displacement : 10.2 e-3 mm Min Safety Factor : 1.35

Ain Shams University Racing Team’17 _Formula Student

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Design Data Report

Stress analysis for the Trunion

Material : Aluminum 6061 Max Stress : 60.6 MPa Displacement : 12 e-3 mm Min Safety Factor : 4.54

Ain Shams University Racing Team’17 _Formula Student

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Design Data Report

Performance design Results and your comments:

Ain Shams University Racing Team’17 _Formula Student

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Design Data Report

Ain Shams University Racing Team’17 _Formula Student

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Design Data Report

Matlab Results At u = 0.8

Front Limit

Ain Shams University Racing Team’17 _Formula Student

Rear Limit

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Design Data Report

Matlab Results At u = 1.2

Front Limit

Ain Shams University Racing Team’17 _Formula Student

Rear Limit

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Design Data Report

Acceleration Curves µ= 1.2

µ= 0.8

Ain Shams University Racing Team’17 _Formula Student

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Design Data Report

Rules Check Single Control for braking system: One pedal mounted in pedal box and linked with the (1 or 2 ) master either by linkage or bias bar Concerning T7.1.1 Can we use a Tandem master cylinder instead of using 2 separate master cylinders, as it also have 2 independent hydraulic circuits

If the tandem cylinder has 4 outlets , can we use proportional valves on the rear outlets to decrease rear circuit pressure and guarantee that front axle locks first.

Ain Shams University Racing Team’17 _Formula Student

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Design Data Report

Braking System Components:

Balance Bar: - Distribute the Pedal Force using the Balance Bar ratio which can be adjusted Master Cylinder: - Support the brake system with the hydraulic line pressure based on the piston diameter. PL = F M/C / A M/C 3. Calliper: - Convert the hydraulic line pressure into clamping force transformed to the pad based on the calliper piston diameter. F clamping = PL * A calliper 4. Pad: - Convert Clamping force into friction force applied to the rotor, which is the main function of the braking system. F f = F clamping * µ f * 2 5. Rotor: - Transform the friction force to braking torque based on the effective radius of the rotor. This is a point at which the pad is assumed to be acting and for our purposes we assume it to be the midpoint of the inner and outer radii of the rotor. T b = F f * R effective

BB Lengths Calculation L * Brake Ratio Front = a L * Brake Ratio Rear = b a+b = L

Approved By: ……………………………………………………………. Ain Shams University Racing Team’17 _Formula Student

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