Publication Date

Spring 5-3-2026

Document Type

Student Project

First Advisor

Dr. Iman Salehinia

Second Advisor

Dr. Bobby Sinko

Degree Name

B.S. (Bachelor of Science)

Department

Department of Mechanical Engineering

Abstract

This project addresses the need for a reliable and validated brake rotor for the Northern Illinois University Formula SAE vehicle following a prior catastrophic rotor failure within the team. Brake rotors in high-performance applications are subjected to significant thermal and mechanical loads, and inadequate design can lead to failure, posing serious safety risks and limiting vehicle performance. To solve this issue, a new brake rotor was designed alongside a dedicated test stand to both improve braking performance and enable experimental validation. The rotor was evaluated using finite element analysis (FEA), including transient thermal and structural simulations, to predict maximum temperature, stress, deformation, and factor of safety under representative braking conditions. Material selection and rotor patterning were optimized, leading to the selection of 17-4PH stainless steel with drilled hole patterns for both rotors. The final front rotor reduced maximum temperature from 378.01°C to 356.49°C while increasing the factor of safety to 2.45, and the rear rotor reduced maximum temperature from 278.27°C to 259.68°C with a factor of safety of 3.24. In parallel, a flywheel-based test stand was developed to simulate real-world braking by matching vehicle kinetic energy, allowing controlled testing and data collection. The test stand provides speed, temperature, and brake pressure measurements to validate simulation results and support future design iteration. This outcome improves braking safety and reliability while establishing a validated engineering approach that integrates simulation, manufacturing, and experimentation for a more competitive Formula SAE vehicle.

Suggested Citation

Boyden, Alexander; Coyne, Austin; and Marko, Cody. “NIU FSAE Brake Rotor Design & Flywheel-Based Test Stand Development.” MEE 486 Final Project Report, Northern Illinois University, 2026.

Download

Share

COinS