Brake Caliper

As part of the 6th semester course Component Design and Material Selection the term project involved designing one system from among a provided list. I selected a brake caliper for an ultralight aircraft. The deliverables for the project included an design statement summarizing initial research and considerations, a progress update, a video presentation covering both the decision making process and the final product, and a design report encompassing all the analysis, material selection, and research performed throughout.

Both manual and simulated stress analysis methods were performed in the development of the product. Conventional calculations provided initial estimates for sizing and a guide for determining material performance. Simulations confirmed these designs and ensured parameters such as deflection remained within reasonable bounds. All computation methods for the assignment were performed in ANSYS 2021 R2 Student.

Similar methods were also applied for thermal analysis. This was similarly significant for material selection and sizing to ensure that the temperature remained reasonable ensuring the material maintains its strength, and guaranteeing that the brake has sufficient capacity to absorb and dissipate enough kinetic energy.