Desenvolvimento de pinça de freio para aplicação em projeto baja SAE

Abstract

This work involved the university extension project Baja SAE, which aims to challenge students to apply the knowledge obtained in the classroom to the development and construction of an off-road vehicle, regulated by the Society of Mobility Engineers (SAE). Through this premise, the project aims to prepare students for the professional environment. The objective of this work is to develop a brake caliper for the Baja prototype of Equipe Imperador UTFPR Curitiba. During recent competitions and tests, Equipe Imperador vehicle became unable to move due to the warping of the rear wheel, which caused damage to the brake system and the prototype’s wheel itself. In addition to this critical failure milestone, the current rear brake system is currently adapted from a commercial caliper, which has dimensions and characteristics that hinder inspection and maintenance. Therefore, this work has established specific objectives aimed at implementing improvements in reliability and interface with other systems, ensuring better caliper and wheel packaging with optimized dimensions, facilitating assembly and maintenance processes. To develop this project, it was necessary to perform calculations to discover the stresses suffered by the component, CAD software modeling, structural resistance evaluation by simulation using FEA, prototype manufacturing, and field validation of the component. The project methodology, Pahl & Beitz, was adapted, containing the stages: informational, conceptual, preliminary, and detailed. After the stages, field tests were carried out to validate the project. Thus, the implementation of this new component resulted in better safety and accessibility for inspections, due to it is geometry designed for the vehicle, which allowed an increase in the distance to the wheel of approximately 20 mm, the repositioning of the banjo and bleeder screws, and upper opening for quick viewing of the braking pads. Changes that will contribute to a reduction in critical failure risks, better team results in future competitions, and interchangeability for subsequent vehicles.