Mechanical DesignCompleted
May 2024
Reverse Engineering — Bicycle Disc Brake System
Group Project - Asiri Sandakelum, Saniru Abhesinha, Tharindu Gamage, Lochini Rubashinhe, Mineth Bhanula
Fusion 360
FEA
Generative Design
Materials
01 — Overview
Performed comprehensive reverse engineering of a bicycle disc brake system including material characterization, 3D modeling, FEA simulation, and generative design optimization.
02 — Problem Statement
Understanding the design intent and material selection of existing brake systems is essential for iterative improvement. Reverse engineering provides insights not available in commercial documentation.
03 — Objectives
- 01Identify materials via burn tests, density measurements, and Rockwell hardness tests
- 02Create accurate 3D models from physical measurements
- 03Perform FEA to validate structural performance
- 04Apply generative design for weight reduction
04 — Key Outcomes
Multi-method material identification: burn tests, density, Rockwell hardness
High-accuracy 3D reverse-engineered models in Fusion 360
FEA stress and thermal analysis under braking loads
Generative design achieving 23% weight reduction
05 — Tools & Technologies
Fusion 360FEAGenerative DesignMaterial Testing