MECH ENG 3E05

Project Progress Report I

Hisham Elkholy 0744637

Sameh Helmy 0840041

Jimmy Tam 0853392

Nick Li 0759935

Chris Kazmierczak 0766589

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MECH ENG 3E05 Progress Report I
SPI: Dr. Wu

Table of Contents
Executive summary................................................................................................................................................ 3
Executive summary................................................................................................................................................ 3
Introduction............................................................................................................................................................... 3
Background................................................................................................................................................................ 4
Cross Drilled......................................................................................................................................................... 4
Liquid Cooled Brakes........................................................................................................................................ 5
Formula 1 Brakes............................................................................................................................................... 5
Comparison Chart............................................................................................................................................... 6
Material selection.................................................................................................................................................... 8
Conceptual Designs:............................................................................................................................................... 8
Centrifugal Pump Disc...................................................................................................................................... 8
Advantages:...................................................................................................................................................... 9
Disadvantages:................................................................................................................................................ 9
Water Cooled Foam Brake.............................................................................................................................. 9
Advantages:...................................................................................................................................................... 9
Disadvantages:................................................................................................................................................ 9
Air Duct Cooling With Heat Sinks.............................................................................................................. 10
Advantages:................................................................................................................................................... 10
Disadvantages............................................................................................................................................... 10
Decision................................................................................................................................................................ 10
Appendix.................................................................................................................................................................. 12
Citations............................................................................................................................................................... 12

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MECH ENG 3E05 Progress Report I
Executive summary

The purpose of this report is to outline the design process used to solve the
problems pertaining to rally racing brakes, such as heat generation, dust infiltration,
impact restitution and reliability. Thorough research was done on current designs
to identify and analyze their pros and cons. The main ones being water-cooled, ram
air duct cooled and cross-drilled disk brakes. Using this knowledge, several
conceptual designs were created to minimize the rally racing braking issues more
effectively than the current designs, including; water foam cooled, centrifugal pump
style rotor and redesigned ram air styled duct with heat sink brake systems. Further
analysis was completed for the concept designs identifying and comparing their
advantages and disadvantages for each. It was determined the ram air duct with
heat sink braking system had the most potential for resolving the braking issues.
The next progress report will provide the details of the engineering analysis
performed on the best concept selected.

Introduction

The objective of this project is to design a braking system for rally cars, for
gravel surfaces. The braking system will include rotors, brake pads, calipers, cooling
system and bias control. In addition to the brakes, this system will require an anti-
lock braking system (ABS) computer, which must be purchased rather than
designed since it is outside the scope of this course. The rotors, brake pads and
calipers will be designed for safety, reliability and cost. The brake basis will be the
conventional hydraulic brake design with improvements to make the design
efficient, light, as cheap as possible but not cheaper, reliable, and effective. The
guidelines for this design will be the FIA regulations for the S2000 World Rally
Championship [1].

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MECH ENG 3E05 Progress Report I
Background
 
Rallying is one of the greatest and most popular categories in motorsports.
It infuses the courage and skills of each individual pilot with their trust in the pace-
notes of their co-driver to propel the car at mind bending speeds through all types of
terrain. Rally is not just a mix of flamboyant display of sideways car control and
lightning speeds through narrow roads on different terrains.  As much as the skills
of the pilot can lead to winning a race, the technology in each rally car is just as
important.
 
            Being quick in any rally stage means going fast for the majority of the course.
Therefore, not only is a car being quick on straights important, but also its ability to
slow down quickly for corners as well. In the many corners of any rally stage, the
brakes are repeatedly used and creates high temperate in both the brake pads and
the brake rotors. This can lead to a decrease in the coefficient of friction on the pads,
warping of the brake disc and boiling of the brake fluid, which decreases the
responsiveness of the brakes. A cooling system needs to be implemented to remove
the negative effects of repeated hard brakes.

Cross Drilled

Cross drilled brakes work as conventional hydraulic brakes do. 2 pads on

either side of a spinning rotor are pushed against it via hydraulic pressure. The
difference is cross drilled brakes have holes drilled through the rotors for cooling.
This is also saves weight. However, the holes are areas of high stress concentration
and will cause the brake to fail much quicker when compared to undrilled rotors.

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MECH ENG 3E05 Progress Report I
 Cross Drilled Brakes [2]

Liquid Cooled Brakes

Liquid Cooled brakes are also work in the same way, pads and hydraulic
pressure, but are cooled using water or, for high performance applications, fluids
with high boiling points as the temperature of brake fluids can get as high as 120 oC.
Fluid is directed at the rotors via a pipe system from a dedicated reservoir.

Formula 1 Brakes

Formula 1 brakes are cooled via air ducts on the inside of the wheels. Air is
channeled to the rotors.

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MECH ENG 3E05 Progress Report I
 Formula 1 Brakes [3]

Comparison Chart

Cross-drilled Liquid Cooled Formula 1 Air duct

Advantages  Better cooling  Most effective  More effective
than non drilled cooling of the 3; than cross
rotors;  Can cool at any drilling;
 Less material speed.  No reservoir
means less required so less
weight. added weight
compared to
liquid cooled.

Disadvantages  Holes mean  May require a  In rally stages, in

stress reservoir which adds this case gravel,
concentration; weight; rocks and
 Cooling at low  Fluid on the rotors pebbles may go
speeds is more or may decrease the through the duct
less like non coefficient of friction; and damage the
drilled rotors.  If water is used, or a brakes;

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MECH ENG 3E05 Progress Report I
 fluid with a relatively  Less effective
low boiling than liquid
temperature, gaseous cooling;
boundaries may be  The duct is big
created between and would not
rotors and pads; fit on a
 If water is used, at production car,
such high rally cars are
temperatures rust is based on
more likely to occur. production cars;
 Pads are not
cooled.

Material selection

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MECH ENG 3E05 Progress Report I
 The most widely used material for the brake rotor in Motorsports are carbon
ceramic and steel. Carbon ceramic brakes offer superior heat dissipating capabilities
and structural rigidity at high temperature, however they offer low impact
resistance. This is crucial in rally racing as the cars encounter frequent impacts with
the road and debris will repeatedly stress the rotors upon impact [4]. Steel brake
rotors will deform under high temperatures, but has a much higher impact
resistance value and offer higher percentage strain to failure [4]. Although the steel
brake rotors will offer a much more reliable brake system, they require more
cooling to operate. As a result the conceptual designs use steel as the material for
the brake rotors.

Brake pad materials are made of complex composites and will not be design
due to the accessibilities to superior quality materials that can be purchased from an
aftermarket source and outside of the scope of this design due to the vast analysis of
new composite materials.

Conceptual Designs:
 

Centrifugal Pump Disc

Using the rotating motion of the disc during drive, the fins between the two
surfaces of the disc rotors can be used as a centrifugal pump to pass air through the
center and flow out radially to cool the brake rotors.
(Appendix Figure 1)

Advantages:
-          Supreme cooling capabilities without any exterior mechanical sources
-          Extra parts are not required
-          Simple assembly

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MECH ENG 3E05 Progress Report I
-          Lightweight

Disadvantages:
-          Stress concentrations on the reduced surface area
-          Difficult to manufacture (Complex Shape )
-          Smaller surface area for cooling
-          Build up of gaseous layer boundary during high speeds
-          Does not work as efficiently at low speeds
 

Water Cooled Foam Brake

               
Water is piped from a reservoir and sprayed a water retaining heat proof
foam pad and in contact constantly with the brake rotors.
(Appendix Figure 2)

Advantages:
-          Good cooling capabilities
-          No aerodynamics required
-          Can work at any speed
-          Wipes dust off
-          Consistent water flow

Disadvantages:
-          Weight increase
-          Buildup of wet clumps of dust around foam
-          Foam may thermally decompose
-          Requires lot water
-          Decrease in speed due to constant friction against the brake rotors
-          Complicated setup/maintenance

Air Duct Cooling With Heat Sinks

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MECH ENG 3E05 Progress Report I
 A ram air style duct will pass airflow through a specially designed brake
caliper with a pin style heat sink protruding out of the brake pads and a branching
duct will direct the air onto the rotors.
(Appendix Figure 3)
 

Advantages:
-          Does not require extra weight (i.e. no reservoir)
-          Has more airflow than centrifugal design (refer to above)
-          Cooling of both the pads and the rotors
-          Small amount of parts
-          Easy to replace

Disadvantages
-          Complex aerodynamics duct part will be difficult to manufacture
-          Requires custom design pads and calipers
-          Increased aerodynamic drag
-          Filter on entrance is required

Decision

Upon considerations of many possible conceptual designs, the chosen design

is to be the ram air duct with heat sink design due to its many advantages. Its
lightweight can increase the reaction rate of the spring due to the decrease in
unsprung mass. This allows the car to respond better and allow for quicker
cornering. Using air-cooled brakes does not require installation of a water reservoir,
which increases the weight of the car and requires to be refilled. With its
minimalistic amount of parts, it can be easily replaced when the aerodynamic
package is damaged. Using steel brake rotors that are prone to warping under high
temperatures, an efficient cooling system must be in place. Brake pads work within

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MECH ENG 3E05 Progress Report I
a limited range of temperatures, and braking efficiency decreases under extreme
heat. The selected design allows for cooling of the brake pads using a heat sink and
the cooling of the rotors. Many of the issues are being resolved most effectively by
this design. This design has the most potential for further development and analysis.

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MECH ENG 3E05 Progress Report I
Appendix

Citations:

[1] Article 255A – 2011, Specific Regulations for Super 200 (Rallies) / WRC;
[Online] http://argent.fia.com/web/fia-
public.nsf/92B8777DD7239078C1257802003B3157/$FILE/255A_2011.pdf
[2] Cross Drilled Brake; [Online];
http://www.bestbrakes.com/images/sp_drilled_sm.jpg

[3] Formula 1 Brake; [Online];

http://www.formula1.com/news/technical/2010/842/807.html

[4] Philosophical Transactions of the Royal Society of London. Series A, Mathematical

and Physical Sciences,Vol. 294, No. 1411, New Fibres and Their Composites (Jan. 21,
1980), pp.583-590

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MECH ENG 3E05 Progress Report I