College
College of Engineering and Polymer Science
Date of Last Revision
2025-04-26 12:09:37
Major
Mechanical Engineering
Honors Course
MECE 461 & MECE 497
Number of Credits
4
Degree Name
Bachelor of Science
Date of Expected Graduation
Spring 2025
Abstract
Brake rotors can develop uneven spots over time, causing vibration and poor braking performance. Commercial brake lathes are effective but often too expensive or complicated for at-home mechanics. This project aimed to create a low-cost tool, around $200–$300, to resurface four rotors in under two hours. We explored two main designs: a pad file system and a motorized endmill powered by a handheld drill. Calculations ultimately showed that the pad file was not viable, so the final prototype produced was the endmill-based design. Our testing showed we were limited by poor stiffness in the endmill and unforeseen loading. Although the prototype did not meet the target performance, we determined the causes for the prototype tool's failure. We formulated two potential ways to revise the design with these failures identified.
Research Sponsor
David Peters
First Reader
Gopal Nadkarni
Second Reader
Scott Sawyer
Honors Faculty Advisor
Scott Sawyer
Proprietary and/or Confidential Information
No
Recommended Citation
Morgan, Raider and Vaughan, Benjamin, "Cost-Effective Brake Rotor Resurfacing Tool" (2025). Williams Honors College, Honors Research Projects. 1958.
https://ideaexchange.uakron.edu/honors_research_projects/1958
Included in
Computer-Aided Engineering and Design Commons, Manufacturing Commons, Other Mechanical Engineering Commons