Design of Brake Rotor (Disc Brake) for Quad Bike (All-Terrain Vehicle)
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Project Spotlight: High-Efficiency Brake Rotor Design for Quad Bike
Location: India
Date: January 2020
In a groundbreaking initiative aimed at redefining vehicular safety and performance, I took on the challenge of designing a high-efficiency brake rotor for Quad Bikes (All-Terrain Vehicles). The project's ambition was not only to meet industry standards but to significantly surpass them, which was achieved with remarkable results.
Project Overview
Utilizing the sophisticated design capabilities of Solidworks and the thermal analysis power of Ansys Workbench, I developed a brake rotor that achieved an unprecedented 74.67% efficiency. This performance exceeded the initial project requirements by nearly 5%, establishing a new high in brake rotor engineering.
Key Achievements
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Precision Engineering: My design played a crucial role in enabling a Quad Bike to achieve a precise stopping distance of 10 meters, crucial for competitive scenarios at the national level.
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Advanced Thermal Analysis: I employed Ansys Workbench for thorough thermal analysis, ensuring the brake rotor’s design was robust under real-world conditions. My innovative approach to vent hole configurations significantly enhanced cooling efficiency, optimizing performance under extreme usage scenarios.
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RESULTS AFTER DOING THE ANALYSIS ON FRONT ROTOR
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Max factor of safety=15
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Min factor of safety=1.3885
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Max heat flux=0.16547 W/mm^2
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Min heat flux=0.0024976 W/mm^2
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Max total deformation=1.9447mm
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Min total deformation=0mm
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Max temperature=86.911 degree Celsius
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Min temperature=71.717 degree Celsius
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RESULTS AFTER DOING THE ANALYSIS ON REAR ROTAR
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Max factor of safety=15
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Min factor of safety=13.392
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Max heat flux=0.18141 W/mm^2
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Min heat flux=0.00027932 W/mm^2
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Max total deformation=0.041096mm
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Min total deformation=0mm
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Max temperature=130.27degree Celsius
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Min temperature= 47.24degree celsius
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Material Selection: I chose Aluminum Alloy 6063 for its superior thermal properties and lightweight characteristics, making the rotor 20% lighter than standard offerings. This strategic decision minimized thermal expansion, improving braking efficiency and extending the rotor's lifespan.
Impact and Innovation
This project stands as a testament to our commitment to innovation, safety, and excellence. By pushing the boundaries of mechanical design and thermal analysis, we have contributed to the advancement of automotive engineering, offering solutions that ensure higher safety and efficiency for all-terrain vehicles.
Looking Ahead
The success of this project has paved the way for further innovations in vehicle design and safety mechanisms. As we continue to explore new technologies and materials, our focus remains on developing solutions that meet the evolving needs of the automotive industry, ensuring vehicles are not only faster and more efficient but safer and more reliable.