Brake Caliper Design for a Formula Student Race Car - On Behalf of Revolve NTNU

Abstract

With the large amount of dynamic loads and heat the brake system of a Formula Student race car experiences, the system requires resistance to both heat and external loads in several of its components. The brake caliper, which holds a pair of two or more brake pads, and actuates them towards a brake rotor to stop a vehicle in motion, is a complex component which often is bought from external suppliers by Formula Student teams. This thesis aims to redesign the brake calipers for Revolve NTNU's race car of 2018, Atmos. Based on a combination of simplified models describing the vehicle's behavior, models describing the brake calipers' behavior, and preliminary data of the vehicle, loading conditions for the brake calipers have been defined and evaluated. Suitable production methods have been investigated and evaluated, and models designed for additive manufacturing and traditional machining processes were developed through topology optimization conducted in TOSCA. Verification analyses were carried out in Abaqus/CAE, where the results were used for both design verification, fatigue-life analyses conducted in fe-safe, and for comparison with mechanical test results of the produced brake calipers. The simulation models were verified by in-lab tests and will be validated by on-track validation during 2018. Redesigning the brake calipers has yielded an unsprung mass reduction in the suspension system of approximately 500 grams in total. Furthermore, the design optimization has been a contributing factor to a total unsprung mass reduction of over 700 grams in other components of the suspension system of Atmos.