Year 3 Semester 1 (2023-2024)

Engineering Design and CAD/CAM

OM2043
CW Assignment

Module Tutor: Alex Bernard

Task – A:

1- Specifications of the mechanical components need to design the EPB shows

below:

-Input shaft:
𝑀 = 2500 𝑁 − 𝑚 = 2.5 × 106 𝑁 − 𝑚𝑚
; 𝑇 = 8000 𝑁 − 𝑚 = 8 × 106 𝑁 − 𝑚𝑚;
𝜎𝑡𝑢 = 600 𝑀𝑝𝑎 = 600 𝑁/𝑚𝑚2 ;
𝜏𝑢 = 400 𝑀𝑝𝑎 = 400 𝑁/𝑚𝑚2

-Output shaft:
: 𝑀 = 5000 𝑁 − 𝑚 = 5 × 106 𝑁 − 𝑚𝑚
; 𝑇 = 12000 𝑁 − 𝑚 = 12 × 106 𝑁 − 𝑚𝑚;
𝜎𝑡𝑢 = 410 𝑀𝑝𝑎 = 410 𝑁/𝑚𝑚2 ;
𝜏𝑢 = 320 𝑀𝑝𝑎 = 320 𝑁/𝑚𝑚2

-Gear box:
𝑃 = 20 𝐾𝑤 = 20000𝑤
𝐷𝐺
𝑉. 𝑅 = =2
𝐷𝑝
𝑁𝑝 = 180 𝑟𝑝𝑚
𝐿 = 500𝑚𝑚
𝑁
𝜎𝑜𝑝 = 𝜎𝑜𝑔 = 55 𝑀𝑝𝑎 = 5 𝑚𝑚2
𝑏=8𝑚
𝑐 = 75
𝐾 = 1.4
-Brake:
𝑚 = 1400𝑘𝑔
𝑆𝑙𝑜𝑝𝑒 = 1: 4
𝑣 = 60 𝑘𝑚/ℎ
ℎ = 40𝑚
𝑑 = 550 𝑚𝑚 𝑜𝑟 𝑟 = 275 𝑚𝑚 , 𝑟 = 0.275
𝑚𝑏 = 18 𝐾𝑔
𝒸 = 470 𝐽/𝐾𝑔℃
2-
-Electric motor simply defines as a device that convert the electrical energy
into mechanical energy. It made from certain materials that have magnetic and
electric properties to function the motor properly.
Copper is one of the most common used materials in electric motor, it is used
for the winding ability of the electromagnetic coils into the motor, which
generates the magnetic field that operates the rotor, in addition copper used
for its excellent conductivity and highly resistant to corrosion. Aluminum
used in the rotor due to its light weight and excellent thermal conductivity.

-Gears: Cast iron is the most common material used in gears due to its good
wearing properties, machinability, and the ease of producing complicated
shapes via metal casting.

-Spindle piston: Cast iron is common material used in spindle piston due to
its strength and durability.

-Parking brake latch: Steel is used in the latch due to high strength and high
performance.

-Brake pads the most used is semi-metallic, it has a percentage range from
30% to 65% metal in addition to materials including wire, steel wool, copper
and others. Semi-metallic has a robustness that making brake pads resistant to
heat and highly performance. Strength and durability

-Brake anchor: Aluminum is the most material used in caliper in the modern
vehicle due to its light weight which improves both fuel economy and the
quality of the ride.

-Brake disc: Cast iron is widely used in brake disc due to less cost and its
excellent thermal conductivity which makes the dissipation easier generated
by the friction of the brake pads during the stop.
 3- When the driver operates the switch of the electric parking, the
electric motor generated the power and transmitted through the
shaft one which turns the gear bow therefore the power will return
the shaft which is connected to the spindle piston then the brake
pads will be forced on the brake disc. Thus, it restricts the moment
of wheels.

Task – B:
4- ISO 26262 is the global standard for electrical and electronic systems applies
in motor vehicle, it provides the conditions and procedures needed to function
the motor safely. SAE J1939 applies to brake pads, sensors, gearbox, electrical
motor and other components manufacturing by this standard, it provides the
procedures of transferring commands the data. DIN 3990 right and accepted
method for design gear load capacity, it provides the procedures and
calculations needed to determine gear’s wear, static and dynamic loads. SAE
J2522 followed for testing disc brake in light vehicle.
5- We have 2 shaft one input and second output, according to the data given
above for the shaft the diameter for each will be calculated:

Given: 𝑀 = 2500 𝑁 − 𝑚 = 2.5 × 106 𝑁 − 𝑚𝑚 ; 𝑇 = 8000 𝑁 − 𝑚

= 8 × 106 𝑁 − 𝑚𝑚; 𝜎𝑡𝑢 = 600 𝑀𝑝𝑎 = 600 𝑁/𝑚𝑚2 ; 𝜏𝑢 = 400 𝑀𝑝𝑎 =
400 𝑁/𝑚𝑚2

As we know that the allowable tensile stress,

𝜎𝑡𝑢 600
𝜎𝑡 = = = 100 𝑁/𝑚𝑚2
𝐹. 𝑆. 6
And allowable shear stress,

𝜏𝑢 400
𝜏= = = 66.67 𝑁/𝑚𝑚2
𝐹. 𝑆. 6

Let 𝑑 = 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑠ℎ𝑎𝑓𝑡 𝑖𝑛 𝑚𝑚

According to maximum shear stress theory, equivalent twisting moment,

𝑇ℯ = √𝑀2 + 𝑇 2 = √(2.5 × 106 )2 + (8 × 106 )2 = 8.38 × 106 𝑁 − 𝑚𝑚

We also know that equivalent twisting moment (𝑇ℯ ),
𝜋 𝜋
8.38 × 106 = × 𝜏 × 𝑑3 = × 66.67 × 𝑑3 = 13.09 𝑑3
16 16

3
8.38 × 106
𝑑 =
13.09
𝑑 = 86.18 𝑚𝑚
According to maximum normal stress theory, equivalent bending moment,
1 1
𝑀ℯ = 2 ( 𝑀 + √𝑀2 + 𝑇 2 )= 2 (𝑀 + 𝑇ℯ )
1
= (2.5 × 106 + 8.38 × 106 ) = 5.44 × 106 𝑁 − 𝑚𝑚
2

Also, as we know that the equivalent bending moment (𝑀ℯ ),

𝜋 𝜋
5.44 × 106 = × 𝜎𝑡 × 𝑑3 = × 100 × 𝑑3 = 9.81 𝑑3
32 32
 5.44 × 106
3
𝑑 =
9.81
𝑑 = 82.15 𝑚𝑚

Taking the larger of the two values, we have

𝑑 = 86.18 𝑚𝑚 𝑠𝑎𝑦 90 𝑚𝑚
We approximated the value according to industry standards.

Second shaft
Given: 𝑀 = 5000 𝑁 − 𝑚 = 5 × 106 𝑁 − 𝑚𝑚 ; 𝑇 = 12000 𝑁 − 𝑚
= 12 × 106 𝑁 − 𝑚𝑚; 𝜎𝑡𝑢 = 410 𝑀𝑝𝑎 = 410 𝑁/𝑚𝑚2 ; 𝜏𝑢 = 320 𝑀𝑝𝑎 =
320 𝑁/𝑚𝑚2

As we know that the allowable tensile stress,

𝜎𝑡𝑢 410
𝜎𝑡 = = = 68.333 𝑁/𝑚𝑚2
𝐹. 𝑆. 6
And allowable shear stress,

𝜏𝑢 320
𝜏= = = 53.33 𝑁/𝑚𝑚2
𝐹. 𝑆. 6

Let 𝑑 = 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑠ℎ𝑎𝑓𝑡 𝑖𝑛 𝑚𝑚

According to maximum shear stress theory, equivalent twisting moment,

𝑇ℯ = √𝑀2 + 𝑇 2 = √(5 × 106 )2 + (12 × 106 )2 = 13 × 106 𝑁 − 𝑚𝑚
We also know that equivalent twisting moment (𝑇ℯ ),
𝜋 𝜋
13 × 106 = × 𝜏 × 𝑑3 = × 53.33 × 𝑑3 = 10.47 𝑑3
16 16

3
13 × 106
𝑑 =
10.47
𝑑 = 107.47𝑚𝑚

According to maximum normal stress theory, equivalent bending moment,

1 1
𝑀ℯ = 2 ( 𝑀 + √𝑀2 + 𝑇 2 )= 2 (𝑀 + 𝑇ℯ )
 1
= (5 × 106 + 13 × 106 ) = 9 × 106 𝑁 − 𝑚𝑚
2
Also, as we know that the equivalent bending moment (𝑀ℯ ),
𝜋 𝜋
9 × 106 = × 𝜎𝑡 × 𝑑3 = × 68.333 × 𝑑3 = 6.708 𝑑3
32 32
3
9 × 106
𝑑 =
6.708
𝑑 = 110 𝑚𝑚

Taking the larger of the two values, we have

𝑑 = 110 𝑚𝑚

Task – C:

𝐷𝐺
6- Given that: 𝑃 = 20 𝐾𝑤 = 20000𝑤, 𝑉. 𝑅 = = 2 ; 𝑁𝑝 =
𝐷𝑝
𝑁
180 𝑟𝑝𝑚 ; 𝐿 = 500𝑚𝑚; 𝜎𝑜𝑝 = 𝜎𝑜𝑔 = 55 𝑀𝑝𝑎 = 5 ;𝑏 =
𝑚𝑚2
8 𝑚 ; 𝑐 = 75; 𝐾 = 1.4

We know that center distance between the shafts (L),

𝐷𝑝 𝐷𝐺 𝐷𝑃 2𝐷𝑝
500 = + = + 2 = 1.5𝐷𝑃 ∵ 𝐷𝐺 = 𝑉. 𝑅 × 𝐷𝑃
2 2 2
500
∴ 𝐷𝑃 = = 333.33 𝑚𝑚 = 0.333 𝑚
1.5
𝐷𝐺 = 2𝐷𝑃 = 2 × 333.33 = 666.66 𝑚𝑚 = 0.666 𝑚
Since both the gears are made of the same material, therefore pinion
is the weaker. Thus, the design will be based upon the pinion.
We know that pitch line velocity of the pinion,
𝜋𝐷𝑃 . 𝑁𝑝 𝜋 × 0.333 × 180
𝑣= = = 3.13 𝑚/𝑠
60 60
Since v is less than 12 m/s, therefore velocity factor,
 3 3
𝐶𝑣 = = = 0.488
3 + 𝑣 3 + 3.13
We know that number of teeth on the pinion,
𝐷𝑃 333.33
𝑇𝑃 = =
𝑚 𝑚
∴ Tooth form factor for the pinion,
0.841 0.841×𝑚
𝑦𝑃 = 0.175 − = 0.175 − ..(For 20° stub system)
𝑇𝑃 333.33
= 0.175 − 0.0025𝑚 (i)
We know that design tangential tooth load,
𝑃 20000
𝑊𝑇 = × 𝐶𝑠 = × 1 = 6389.7 𝑁
𝑣 3.13
We also know that tangential tooth load (𝑊𝑇 ),
6389.7 = 𝜎𝑤𝑃 . 𝑏. 𝜋𝑚. 𝑦𝑝 = (𝜎𝑂𝑃 × 𝐶𝑣 )𝑏. 𝜋𝑚. 𝑦𝑝
= (55 × 0.488) 8𝑚 × 𝜋𝑚(0.175 − 0.0025𝑚)
= 118𝑚2 − 1.67𝑚3
𝑆𝑜𝑙𝑣𝑖𝑛𝑔 𝑡ℎ𝑖𝑠 𝑒𝑞𝑢𝑎𝑡𝑖𝑜𝑛 𝑏𝑦 ℎ𝑖𝑡 𝑎𝑛𝑑 𝑡𝑟𝑖𝑎𝑙 𝑚𝑒𝑡ℎ𝑜𝑑, 𝑤𝑒 𝑓𝑖𝑛𝑑 𝑡ℎ𝑎𝑡
𝑚 = 0.85 𝑠𝑎𝑦 9 𝑚𝑚

Face width,
We know that face width,
𝑏 = 8𝑚 = 8 × 9 = 72𝑚𝑚
Number of teeth on the gears
We know that number of teeth on the pinion,
𝐷𝑃 333.33
𝑇𝑃 = = = 37.03
𝑚 9
And number of teeth on the gear,
𝐷𝐺 666.66
𝑇𝑃 = =
𝑚 9
Checking the gears for dynamic and wear load
We know that the dynamic load,
 21𝑣(𝑏. 𝑐 + 𝑊𝑇 )
𝑊𝐷 = 𝑊𝑇 +
21𝑣 + √𝑏. 𝑐 + 𝑊𝑇
21 × 3.13(72 × 75 + 6389.7)
= 6389.7 +
21 × 3.13 + √72 × 75 + 6389.7
774936
= 6389.7 +
174.3
= 10835 𝑁
From equation (i), we find that tooth form factor for the pinion,
𝑦𝑃 = 0.175 − 0.0025𝑚 = 0.175 − 0.0025 × 9
= 0.1525
As we know that flexural endurance limit (𝜎ℯ ) for cast iron is 84
Mpa or 84 𝑁/𝑚𝑚2
∴ Static tooth load or endurance strength of the tooth,
𝑊𝑠 = 𝜎ℯ . 𝑏. 𝜋𝑚. 𝑦𝑃 = 84 × 72 × 𝜋 × 9 × 0.1525 = 26077.98 𝑁
We know that ratio factor,
2 × 𝑉. 𝑅. 2 × 2
𝑄= = = 1.33
𝑉. 𝑅. +1 2 + 1
∴ Maximum or limiting load for wear,
𝑊𝑤 = 𝐷𝑃 . 𝑏. 𝑄. 𝐾 = 333.33 × 72 × 1.33 × 1.4 = 44687.55 𝑁
Since both 𝑊𝑠 and 𝑊𝑤 are greater than 𝑊𝐷 , therefore the design is
safe.

7- Given: 𝑚 = 1400𝑘𝑔; 𝑆𝑙𝑜𝑝𝑒 = 1: 4 ; 𝑣 = 60 𝑘𝑚/ℎ ; ℎ = 40𝑚

𝑑 = 550 𝑚𝑚 𝑜𝑟 𝑟 = 275 𝑚𝑚 , 𝑟 = 0.275 ; 𝑚𝑏 = 18 𝐾𝑔; 𝒸=
470 𝐽/𝐾𝑔℃
Average braking torque to be applied to stop the vehicle.
We know that kinetic energy of the vehicle,
1 1
𝐸𝐾 = . 𝑚. 𝑣 2 = × 1400 × (16.67)2 = 194444.4 𝑁 − 𝑚
2 2
And potential energy of the vehicle,
1
𝐸𝑝 = 𝑚. 𝑔. ℎ × 𝑆𝑙𝑜𝑝𝑒 = 1400 × 9.81 × 40 × 4 = 137340 𝑁 − 𝑚

֒ Total energy of the vehicle or the energy to be absorbed by the

brake,
𝐸 = 𝐸𝐾 + 𝐸𝑝 = 194444.4 + 137340 = 331784.4 𝑁 − 𝑚

Since the vehicle is to be stopped in 40m, therefore tangential braking

force required,
331784.4
𝐹𝑡 = = 8294.61 𝑁
40
We know that average braking torque to be applied to stop the vehicle.
𝑇𝐵 = 𝐹𝑡 × 𝑟 = 8294.61 × 0.275 = 2281.01 𝑁 − 𝑚
Average temperature rise of the drum.
Let ∆𝑡 = Average temperature rise of the drum in ℃
We know that the heat absorbed by the brake drum,
𝐻𝑔 = 𝐸𝑛𝑒𝑟𝑔𝑦 𝑎𝑏𝑠𝑜𝑟𝑏𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑏𝑟𝑎𝑘𝑒 𝑑𝑟𝑢𝑚
= 331784.4 𝑁 − 𝑚 = 331784.4 𝐽
We also know that the heat absorbed by the brake drum (𝐻𝑔 ),
331784.4 = 𝑚𝑏 × ∁ × ∆𝑡 = 18 × 470 × ∆𝑡 = 8460 ∆𝑡
331784.4
∴ ∆𝑡 = = 39.2℃
8460

Minimum coefficient of the friction between the tyre and road

Let 𝜇=
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑡ℎ𝑒 𝑡𝑦𝑟𝑒 𝑎𝑛𝑑 𝑟𝑜𝑎𝑑, 𝑎𝑛𝑑
𝑅𝑁
= 𝑁𝑜𝑟𝑚𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑡ℎ𝑒 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 𝑠𝑢𝑟𝑓𝑎𝑐𝑒. 𝑇ℎ𝑖𝑠 𝑖𝑠 𝑒𝑞𝑢𝑎𝑙 𝑡𝑜 𝑤𝑒𝑖𝑔ℎ𝑡 𝑡ℎ𝑒 𝑣𝑒
= 𝑚. 𝑔 = 1400 × 9.81 = 13734 𝑁
We know that tangential braking force (𝐹𝑡 ),
8294.61 = 𝜇. 𝑅𝑁 = 𝜇 × 13734
8294.61
𝜇= = 0.63
13734
Task – D:

8- Static and variable loadings affect the brake system in several ways.
Static load is that load applied to the brake system while moving of
the vehicle at constant speed. Variable load is changes with time due
to many factors turning the vehicle, acceleration, and deceleration.
Static loads measure the minimum braking force required to
maintain a proper speed, therefore static load affects the tear and
wear of the brake components. Variable load depends on many
factors such as speed, rotating parts and loading condition of the
brake.

9- Robustness design is a process of crating system that can withstand

variations during the operation such as temperature, humidity,
vibration, and noise. Taguchi method used to modify the design of
electric parking brake system for robustness, it is a statistical
technique helps to optimize the design parameters and to minimize
the vibration in output. The Taguchi method included four process,
determine the important design component, choosing an orthogonal
array, running trails and the end evaluation the outcomes to
determine the best factor combination for optimum performance.