Development of a Brake Fluid Pipe Cover

Abstract

Vehicles utilise brakes for safe speed control and stopping, ensuring the safety of passengers, cargo, and others on the road during transportation. The braking process involves the initiation of the brake pedal that allows hydraulic pressure to be transmitted through the brake fluid to the calipers, activating pistons that press the brake pads against the brake disc, ensuring the necessary friction for vehicle deceleration. However, when a vehicle is in motion, certain brake calipers come with a brake fluid pipe that is exposed to road debris, risking operational issues. This bachelor’s thesis aims to provide a solution for the Sarlin Racing Team to safeguard the brake fluid pipe connected to the brake caliper from environmental factors. Sarlin Racing Team is a local company located in Riihimäki, Finland. The firm supplies vehicle parts to enhance customers’ driving experience, ensuring a smooth ride, and improved overall performance for customers’ vehicles. The structure of this thesis constitutes theoretical and empirical components. Initially, a thorough review of the literature on brake calipers, discs, fluid, and their collective impact on vehicle disc brake systems is undertaken. It extends to practical processes, including additive manufacturing, 3D scanning, and reverse engineering. In the practical section of the thesis, a brake caliper is 3D scanned, reverse engineered, modified, and 3D-printed, followed by the creation and evaluation of a brake fluid pipe cover. Finally, the durable cover is affixed to the modified 3D-caliper to bolster the safety of vehicle disc brake systems. This initiative reduces maintenance needs and highlights the fusion of theoretical knowledge and practical expertise for improving vehicle safety.