Date of Graduation

Spring 2015

Document Type

Honors Research Project

Degree Name

Bachelor of Science

Major

Mechanical Engineering

Research Sponsor

Dr. Siamak Farhad

First Reader

Dr. Richard Gross

Abstract

The following report encompasses the design of the 2015 University of Akron’s FSAE formula electric braking system. The system is one based on hydraulic braking and designed for a one man performance racing vehicle. The objective of the system is to convert the kinetic energy of the vehicle into thermal energy, allowing the vehicle to decelerate optimally and safely. The design includes three major categories: calculation and evaluation of the hydraulic system in order to select calipers and master cylinders, the design of the pedal box, and the design of the rotors.

The results and findings of the proceeding report rendered a symmetrical front and rear braking system. The Wilwood Single Dynalite two piston floating caliper and the 77-Series Tilton master cylinders with a 1 inch bore were selected for the system. An optimized pedal box was designed consisting of two pedals, (gas and brake), eight mounting tabs for the two pedals and master cylinders, and two electrical sensor supports (one for the throttle sensor and the other for the emergency stop switch). The pedal box was optimized for minimal mass and satisfied the design criteria (later defined in the text). Lastly, custom rotors were designed based on the optimal material choice, analyzing thermal effects and considering cost.

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