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Abstract

The original front hub for the third generation Chevrolet Camaro Z/28 and Pontiac Trans- Am integrates the brake rotor with the wheel hub. However, owners have been known to replace the integrated wheel/hub with separate aftermarket hubs in order to make brake rotor replacement easier; this is especially true in competitive racing. This project arose after spending time at the race track with a friend, Jeremy Moen, who races his 1991 Camaro Z/28 with aftermarket 6061-T6 aluminum wheel hubs. The aftermarket aluminum hubs did not perform successfully; the hubs failed consistently at the interface between the bearing race and the hub. Tfie goal of this project is to improve the hub design. Finite element analysis was used to model the extreme conditions found on the race track. The temperatures generated from the brakes altered the aluminum's microstructure due to its low melting point, making it much softer than needed for this application. Fatigue analysis confirmed that aluminum was not a suitable. Selection of a better material was narrowed down to stainless steels and high carbon steels, and finally 4340 steel. Taking cues from the original hub that came on the Camaro from the factoiy, three changes in geometry were also made to minimize weight and maintain structural integrity. The final design has a safety factor that exceeds the previously used aluminum hub in both static and fatigue analysis.

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