Project Spotlight: High-Efficiency Brake Rotor Design for Quad Bike

Location: India

Duration: 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:

1. 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.

2.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.

RESULTS AFTER DOING THE	ANALYSIS ON FRONT ROTOR
Max factor of safety	15
Min factor of safety	1.3885
Max heat flux	0.16547 W/mm^2
Min heat flux	0.0024976 W/mm^2
Max total deformation	1.9447mm
Min total deformation	0mm
Max temperature	86.911 degree Celsius
Min temperature	71.717 degree Celsius

RESULTS AFTER DOING THE	ANALYSIS ON REAR ROTOR
Max factor of safety	15
Min factor of safety	13.885
Max heat flux	0.18141 W/mm^2
Min heat flux	0.00027932 W/mm^2
Max total deformation	0.041096mm
Min total deformation	0mm
Max temperature	130.27 degree Celsius
Min temperature	47.24 degree celsius

3.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.