EG-110 CW2: Assignment 2 2023/24 Design and provide a manufacturing drawings for a simplified disk brake rotor set SMOK G The disk brake rotor set will be composed from 3

components: 1. Disk brake 2. Disk brake hub 3. Bolts "( ( ( C Examples of commercial disk brake rotors (for bikes on the left [1], for motorbikes on the right [2]) You will have a significant freedom in the design of the disk rotor components with a minimum number of pre-defined dimensions linked to the LAST 3 digits of your student number; you will have to provide fully dimensioned detail engineering drawings of the components and drawing of the assembly. Disk Brake: The student is free to develop a suitable design for the disk brake hub ensuring the following requirements ● ● ● The disk brake is circular with an outside diameter of (300 +X) mm, where X is the last digit from last in the student number (example 1234567 →7 leading to 307 mm). The disk brake has a uniform thickness of 5 mm. The disk brake has a number of circular holes around the rim to ensure adequate cooling during braking and performance in wet conditions. The diameter and number of holes has to be selected by student. There should be at least 2 rows of holes around the rim. The disk brake has a set of bolt holes to connect it to the disk brake hub. The bolt holes are equi-spaced around the centre at a suitable distance. The bolt holes are straight holes and have a diameter of 10.5mm. The number of bolts holding the two parts together is related to the last two digits (EF) of your student number as follows: Number of bolts in your design Last 2 digits of student number 00-49 50-99 Diameter =300+Xmm 7 5 Straight holes of Ø10.5 mm, number defined by student number Sketch for a design of the disk brake; design does not need to look as figure above: design above has 6 bolt holes you are required either 7 or 5, depending on your student number! Disk brake hub The student is free to develop a suitable design for the disk brake hub ensuring the following requirements: ● ● The disk brake hub has a thickness of 8 mm, with raised centre 5 mm extra thick The disk brake hub has a set of threaded M10x1 holes to connect it to the disk brake. Location and number match the bolt holes on the disk brake. Bolts At the centre there is a circular opening for the shaft, surrounded by 5 threaded M12x1.5 holes. The opening has a diameter of 80 -Y mm, with Y the second from last digit in student number (1234567 → 6). Suitability of design requires to limit weight of component; a design consisting of a simple solid circle is not acceptable. Student is free to propose her/his suitable design. Shaft opening diameter = 80 - Y Select suitable diameter Threaded M12x1.5 holes; 5 equi-spaced around centre Threaded M10x1 holes; Location and number match the bolt holes of disk brake 5 mm thick extra 8 mm thick Sketch for a design of the disk brake hub; design does not need to look as figure above; Design above has 6 threaded M10 holes, you are required either 7 or 5! Bolts are steel, metric 10 mm thread (M10x1) with a thread length of 7 mm, and have a hexagonal hole for a standard Allen key (5 mm across the flats) the hex hole should be at least 5 mm deep, or can be all the way through the part (see picture below). The bolt head is 5 mm high and 18 mm outside diameter. You need to design and draw these bolts as well. They attach directly to threads in the hub. Design of bolt needs to be suitable, hence the bolts need to be long enough to suitably fasten the hub and disk brake. Sketch for a possible design for the bolt; design does not need to look as figure above Assembly The assembly consist of the joining of all components. For this purpose, it is essential that all dimensions of components are compatible. The number of bolts will be the value previously selected based on the last 2 digit of your student number O Recommendations: You are a tasked to create fully dimensioned engineering drawings of the components, not "sketches" A simple clear design is easier to dimension and more likely to be easily and accurately manufactured Dimensioning notes: 1. Firstly, look in "Engineering Drawing Practice BSI 8888" for higher education (see CANVAS link) for examples of dimensioning. 2. Be careful in dimensioning repeated features, please check pages 85 & 86 of above reference document 3. Threads need a thread designation, not the diameter symbol. Replace the diameter dimension with Thread size (e.g. M10x1.0). Threads are shown as conventional representation following BSI standard ( do not model a 3D replica of a thread, see lecture notes) 4. If you have fillets of the same radius, you can add a note at the bottom of the page to say "All fillets radius 4mm unless otherwise stated" is correct ("4mm" is an example, the selected radius can differ) 5. Manufacturing linear and diameter tolerance will be 0.1 mm, hence dimensions should be specified to the nearest 0.1 mm (0.05 mm if a radius) 6. Ask to fellow students to check your drawing Coursework Submission: Engineering Drawings to be submitted online in PDF format. 3 Engineering drawing sheets (A3 BSI format, BSI standards) in total to be submitted: Sheet 1. Front view of the Disk Brake, correctly dimensioned with hidden detail. Scale 1:2. Detail view of a portion of the rim with “cooling” holes, scale 1:1. Add a text note at the bottom of the page to describe its uniform thickness. Sheet 2. Front and side view of the Disk brake hub, correctly dimensioned with hidden details. Scale 1:2. Two orthographic views of the bolt, scale 2:1, correctly dimensioned with hidden details. Sheet 3. Assembly drawing: front, side view with hidden detail; one isometric view without hidden details. Scale is your choice, but 1:2 may be most suitable to fit on the page. No dimensions on this drawing. It should be possible to check that you have correctly assembled the parts from this drawing. There should be the bill of materials. Submission PDF rules 1. Submit in CANVAS through Turnitin only as a single file submission, so you will need to combine your documents into one. Once you have created the independent files in PDF format they can be 'stitched' together by using software in PC labs or through online tools. Save the document and then submit through CANVAS 2. Add, as frontpage of the PDF, the properly compiled "Coursework Submission Sheet" Deadline is posted online on module CANVAS References [1] Hope V2 Floating Disc Brake Rotor [Accessed 10/10/2019] url: https://www.wiggle.co.uk/hope-v2-floating-disc-brake-rotor/ [2] 300mm aluminium alloy Brembo H4 Disc Brake [Accessed 10/10/2019] url: https://www.aliexpress.com/item/32947988153.html