Date of Defense
Dr. Ho Sung Lee
Alan Hendershot, Bendix-Spicer Foundation Brakes
Mike Brown, Bendix-Spicer Foundation Brakes
Abstract The current production rotor designed by Bendix Spicer Foundation Brakes, LLC was failing due to heat cracking during the rotor distress test. Bendix Spicer required analysis and design recommendations for an improved rotor design. The engineering group developed analytical and Finite Element Analysis (FEA) models to simulate the rotor distress test. Using historical test data as the baseline, computational models were developed. By analyzing temperature, an acceptable error of 16.4% was reached. The FEA models were used to analyze Bendix Spicer's new flat plate rotor in order to quantify maximum temperature, maximum effective stress, and displacement. Single factor design studies were set up to analyze the rotor disc thickness of the flat plate rotor, a uniform post design as an alternate interior geometry, and the fillet size associated with the post design. From the rotor disc thickness design study, an inboard disc thickness of 0.74 [in] and an outboard disc thickness of 0.64 [in] generated the best results. The post rotor design study shows that the maximum post diameter produced the best results. It was discovered from the fillet design study that the fillet size had little effect on any of the engineering measurables. However, the engineering group believes the heat cracking is associated with mounting flange constraints. The engineering group recommends that a new connection method between the rotor and hub be developed to allow for thermal expansion.
Cavanaugh, Brian, "Optimization of a Commercial Vehicle Brake Rotor" (2004). Honors Theses. 1944.
Honors Thesis-Campus Only