Improved Thermal Transport for Helical Brake System

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Improved Thermal Transport for Helical Brake
System

• Group Members
• Jim Cloer
• Matt Evonuk
• Arek Gazdowicz
• Dirk Tarman

Industry Sponsor Braking Technologies
Faculty Advisor Dr. David Sailor
Senior Capstone Spring 2005
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The HeliCalTM Brake Caliper

• Improved clamping force to actuation force ratio
• Improved wear characteristics
• Equal pad pressure over entire rotor

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Problem Statement

• Design a new housing for the helical brake
  design that has improved heat dissipation and is
  able to withstand the mechanical stresses placed
  upon it

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Design Goals

• New housing
• Can be incorporated into assembly
• Reduce material usage
• 400 Increase in heat flux
• Reduce the chance of thermal failure
• 2 safety factor

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Chosen Geometry

• Concentric vanes
• Fewer stress concentrations
• Less material
• Ease of manufacture
• Low cost

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Testing

• Options
• - Custom built test stand
• - Baja test stand
• - Place on racing kart
• - Hot plate

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Stress Verification
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Thermal Verification
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Thermal Result
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Final Prototype
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Results

• Safety factor greater than 2
• 300 increase in heat flux
• Adaptable to current design
• Uniform heat flux distribution
• Simplified assembly