FEA | Saikiran Juttu | Robotics Portfoliohttps://juttu-s.github.io/saikiran_juttu.github.io/tags/fea/FEAHugo Blox Builder (https://hugoblox.com)en-usTue, 15 Jan 2019 00:00:00 +0000https://juttu-s.github.io/saikiran_juttu.github.io/media/icon_hu7729264130191091259.pngFEAhttps://juttu-s.github.io/saikiran_juttu.github.io/tags/fea/Brakes & Testing Head — BAJA SAE Off-Road Racinghttps://juttu-s.github.io/saikiran_juttu.github.io/details/brakes_testing_head/Tue, 15 Jan 2019 00:00:00 +0000https://juttu-s.github.io/saikiran_juttu.github.io/details/brakes_testing_head/<h2 id="overview">Overview</h2> <p><strong>Role:</strong> Brakes and Testing Head<br> <strong>Team:</strong> Off-Road Racing Team — NIT Jalandhar<br> <strong>Duration:</strong> Jan 2017 – May 2019</p> <ul> <li>Led end-to-end development of high-performance ATV brake systems.</li> <li>Built India’s <strong>lightest ATV</strong> for BAJA SAE 2019.</li> <li>Achieved <strong>4th fastest ATV</strong> at BAJA SAE Illinois 2017.</li> <li>Delivered robust braking under extreme off-road and endurance conditions. <figure > <div class="flex justify-center "> <div class="w-100" ><img src="https://juttu-s.github.io/saikiran_juttu.github.io/saikiran_juttu.github.io/uploads/experience.jpg" alt="" loading="lazy" data-zoomable /></div> </div></figure> </li> </ul> <hr> <h2 id="full-lifecycle-mechanical-design">Full Lifecycle Mechanical Design</h2> <ul> <li><strong>Concept to CAD:</strong> Designed floating brake calipers and dual-rotor configurations in <strong>Catia V5</strong>.</li> <li><strong>Simulation &amp; Analysis:</strong> Validated all designs using <strong>ANSYS 16.0</strong> (thermal &amp; static structural).</li> <li><strong>Prototyping &amp; Testing:</strong> Built physical test setups using <strong>Arduino, load cells, and sensors</strong>.</li> <li><strong>DFM &amp; Machining:</strong> Translated CAD into manufacturable parts using CNC machining and lathe operations.</li> </ul> <hr> <h3 id="brake-caliper-design--simulation">Brake Caliper Design &amp; Simulation</h3> <p>Developed and validated a custom <strong>floating brake caliper</strong> to suit the geometry of a compact, lightweight ATV with extreme off-road use cases.</p> <ul> <li>Designed from scratch in <strong>Catia V5</strong> to match suspension and rotor configurations</li> <li>Performed <strong>FEA-based stress testing</strong> in <strong>ANSYS</strong> to validate mechanical strength under peak braking loads</li> <li>Conducted <strong>iterative simulations</strong> to minimize deflection and ensure even brake pad wear</li> <li>Assembly designed with DFM principles, ease of maintenance</li> </ul> <h4 id="cad-exploded-view">CAD Exploded View</h4> <p> <figure > <div class="flex justify-center "> <div class="w-100" ><img src="https://juttu-s.github.io/saikiran_juttu.github.io/saikiran_juttu.github.io/uploads/calliper_assembly.jpg" alt="Exploded view of caliper assembly" loading="lazy" data-zoomable /></div> </div></figure> </p> <h4 id="ansys-fea-analysis">ANSYS FEA Analysis</h4> <p> <figure > <div class="flex justify-center "> <div class="w-100" ><img src="https://juttu-s.github.io/saikiran_juttu.github.io/saikiran_juttu.github.io/uploads/caliper_ansys.jpg" alt="FEA Stress Simulation in ANSYS" loading="lazy" data-zoomable /></div> </div></figure> </p> <hr> <h2 id="structural--thermal-analysis-fea">Structural &amp; Thermal Analysis (FEA)</h2> <h3 id="rear-brake-rotor">Rear Brake Rotor</h3> <ul> <li>Conducted <strong>transient thermal analysis</strong> for heat dissipation during prolonged braking.</li> <li>Used vented profiles to reduce thermal hotspots and fade.</li> </ul> <p> <figure > <div class="flex justify-center "> <div class="w-100" ><img src="https://juttu-s.github.io/saikiran_juttu.github.io/saikiran_juttu.github.io/uploads/rear_rotor_thermal.jpg" alt="Rear Rotor Thermal" loading="lazy" data-zoomable /></div> </div></figure> <br> *Rear Rotor — Thermal Simulation *</p> <p> <figure > <div class="flex justify-center "> <div class="w-100" ><img src="https://juttu-s.github.io/saikiran_juttu.github.io/saikiran_juttu.github.io/uploads/rear_rotor.jpg" alt="Rear Rotor Stress" loading="lazy" data-zoomable /></div> </div></figure> <br> *Rear Rotor — Static Structural FEA *</p> <hr> <h3 id="front-brake-rotor">Front Brake Rotor</h3> <ul> <li>Combined <strong>aluminum core</strong> with <strong>SS420 stainless steel coating</strong> for weight and heat resistance.</li> <li>Optimized spoke pattern for mechanical integrity with minimal mass.</li> </ul> <p> <figure > <div class="flex justify-center "> <div class="w-100" ><img src="https://juttu-s.github.io/saikiran_juttu.github.io/saikiran_juttu.github.io/uploads/front_rotor_thermal.jpg" alt="Front Rotor Thermal" loading="lazy" data-zoomable /></div> </div></figure> <br> <em>Front Rotor — Thermal Analysis</em></p> <p> <figure > <div class="flex justify-center "> <div class="w-100" ><img src="https://juttu-s.github.io/saikiran_juttu.github.io/saikiran_juttu.github.io/uploads/Front_rotor.jpg" alt="Front Rotor Stress" loading="lazy" data-zoomable /></div> </div></figure> <br> <em>Front Rotor — Structural Stress Analysis</em></p> <hr> <h2 id="brake-pedal-design--validation">Brake Pedal Design &amp; Validation</h2> <ul> <li>Designed and analyzed <strong>pedal assembly</strong> with custom mount.</li> <li>Validated force distribution using <strong>FEA</strong> and real-time <strong>load cell logging</strong>.</li> </ul> <p> <figure > <div class="flex justify-center "> <div class="w-100" ><img src="https://juttu-s.github.io/saikiran_juttu.github.io/saikiran_juttu.github.io/uploads/Brake_pedal_ansys.png" alt="Brake Pedal ANSYS" loading="lazy" data-zoomable /></div> </div></figure> <br> <em>Brake Pedal — Stress Zones</em></p> <p> <figure > <div class="flex justify-center "> <div class="w-100" ><img src="https://juttu-s.github.io/saikiran_juttu.github.io/saikiran_juttu.github.io/uploads/pedal_mounting.png" alt="Pedal Mounting" loading="lazy" data-zoomable /></div> </div></figure> <br> <em>Custom Bracket — Pedal Mount Geometry</em></p> <hr> <h2 id="prototyping-fabrication--machining">Prototyping, Fabrication &amp; Machining</h2> <ul> <li>Designed parts for <strong>machinability and DFM</strong> — ensured tolerances for <strong>hydraulic caliper</strong> alignment.</li> <li>Utilized <strong>CNC</strong>, <strong>lathe</strong>, and conventional machining techniques for part manufacturing.</li> <li>Fabricated and tested prototypes under simulated track conditions.</li> <li>Assembled and field-tested brake components on the <strong>actual ATV chassis</strong>.</li> </ul> <hr> <h2 id="experimental-testing">Experimental Testing</h2> <ul> <li>Developed a <strong>custom rig</strong> using <strong>Arduino Uno</strong>, <strong>LDR</strong>, and <strong>load cell sensors</strong> to measure: <ul> <li>Acceleration during braking</li> <li>Pedal force vs stopping distance</li> <li>Response time</li> </ul> </li> </ul> <p> <figure > <div class="flex justify-center "> <div class="w-100" ><img src="https://juttu-s.github.io/saikiran_juttu.github.io/saikiran_juttu.github.io/uploads/test.png" alt="Test Rig" loading="lazy" data-zoomable /></div> </div></figure> <br> <em>On-field brake performance testing with Arduino sensor rig</em></p> <hr> <h2 id="tools--skills">Tools &amp; Skills</h2> <ul> <li><strong>CAD:</strong> Catia V5, SolidWorks</li> <li><strong>Simulation:</strong> ANSYS (Thermal, Structural), FEA, hand calculations</li> <li><strong>Prototyping:</strong> CNC, lathe, drilling, aluminum fabrication</li> <li><strong>Testing:</strong> Arduino, load cells, custom rigs</li> <li><strong>Design for Manufacturing (DFM)</strong></li> <li><strong>Material Selection:</strong> Aluminum, SS420, brake pad composites</li> <li><strong>Team Leadership &amp; Documentation</strong></li> </ul> <hr> <h2 id="outcomes">Outcomes</h2> <ul> <li>Reduced brake system weight by <strong>40%</strong>.</li> <li>Increased thermal capacity and structural durability.</li> <li>Enabled modular swap-out of brake parts for different terrains.</li> <li>Competitive performance in national/international SAE racing events.</li> </ul>