Improved Thermal Transport Improved Thermal Transport for Helical Brake Systemfor Helical Brake System

Group Members:Group Members:Jim CloerJim Cloer

Matt EvonukMatt EvonukArek Gazdowicz Arek Gazdowicz

Dirk TarmanDirk Tarman

Industry SponsorBraking Technologies

Faculty AdvisorDr. David Sailor

Senior Capstone Spring 2005

Improved clamping force to actuation Improved clamping force to actuation force ratioforce ratio

Improved wear characteristicsImproved wear characteristics Equal pad pressure over entire rotorEqual pad pressure over entire rotor

The HeliCalTM Brake Caliper

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

Problem Statement

Design GoalsDesign Goals

New housingNew housing• Can be incorporated into assemblyCan be incorporated into assembly• Reduce material usageReduce material usage• 400% Increase in heat flux400% Increase in heat flux• Reduce the chance of thermal failureReduce the chance of thermal failure• 2 safety factor2 safety factor

Chosen GeometryChosen Geometry

Concentric vanesConcentric vanes• Fewer stress Fewer stress

concentrationsconcentrations• Less materialLess material• Ease of manufactureEase of manufacture• Low costLow cost

TestingTesting

OptionsOptions

- Custom built test stand- Custom built test stand

- Baja test stand- Baja test stand

- Place on racing kart- Place on racing kart

- Hot plate- Hot plate

Stress VerificationStress Verification

Thermal VerificationThermal Verification

Thermal ResultThermal Result

150 200 250 300 350 400 450 5000

1

2

3

4

5

6

7

8x 10

4

bottom tempuratre (F)

flux

(Btu

/hr

ft2 )

Heat Flux vs. Bottom Temperature

Original housing

1st. PrototypeTower side

Applied side

Final PrototypeFinal Prototype

ResultsResults

Safety factor greater than 2Safety factor greater than 2 300% increase in heat flux300% increase in heat flux Adaptable to current designAdaptable to current design Uniform heat flux distributionUniform heat flux distribution Simplified assemblySimplified assembly