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Disk Brake Design Case Study Implementation Method and Student Survey Results

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2011 ASEE Annual Conference & Exposition


Vancouver, BC

Publication Date

June 26, 2011

Start Date

June 26, 2011

End Date

June 29, 2011



Conference Session

Project-Based Learning

Tagged Division

Design in Engineering Education

Page Count


Page Numbers

22.505.1 - 22.505.21



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Paper Authors


Oscar G. Nespoli University of Waterloo

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Oscar Nespoli is a Lecturer in Engineering and Mechanical Design and Director of Curriculum Development in the Department of Mechanical and Mechatronics Engineering at the University of Waterloo (Waterloo). Oscar joined Waterloo following a 23-year career in research, engineering and management practice in industry and government. His teaching and research interests are in the areas of engineering design methodologies, design practice, engineering education and high performance, lightweight, composite materials design. Oscar is passionate about teaching engineering and, as part of his current role, maintains strong industry-university relations and a commitment to remain close to engineering design and management practice.

Before joining Waterloo, Oscar held the position of Sr. Program Manager at L-3 Communications Wescam (L-3 Wescam), a manufacturer of airborne surveillance systems for public safety, security and defense markets. Oscar had been employed at L-3 Wescam for 11 years, where he led multi-disciplinary teams toward the successful development and commercialization of several products to various markets. He was responsible for L-3 Wescam’s largest defense programs.

Oscar worked at the Canadian Forces Department of National Defense failure analysis lab, where he was the Canadian Project Officer for an international program on F/A-18 bonded repair, and prior to that, a Research Engineer at the Canadian Space Agency. Oscar designed and qualified space flight hardware for a space experiment for Space Shuttle Flight STS-52 in 1993.

Earlier in his career Oscar led the design and development of products employing composite materials at Owens Corning Canada and contributed to the development of novel production machinery for the footwear industry with Bata Engineering.

Oscar earned a Master of Applied Science degree in Mechanical Engineering specializing in lightweight composite material structures from the University of Waterloo, and a Bachelor of Science degree in Mechanical Engineering from Queen’s University (Kingston, Ontario, Canada). He became a licensed professional engineer in 1986.

Oscar lives in Guelph, Ontario, Canada with his wife Dianne, and they are blessed with three wonderful sons.

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Harry Tempelman Hitachi Construction Truck Mfg Ltd.

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Harry Tempelman is a mechanical engineer who has 25 years of design experience in Aerospace and off-highway vehicles. Prior to joining Hitachi, he was the president of TDT Inc., a consulting company specialized in design, stress analysis, material selection, and manufacturing solutions. He's been with Hitachi Trucks since 2005 as the senior manager of the Technical Analysis Group. The group is currently working on some projects related to truck dynamics, engineering optimization, fatigue analysis, frame/body design, and material selection.

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Ryan Spencer

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Steve Lambert University of Waterloo

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Disk Brake Design Case Study Implementation Method and Student Survey ResultsAbstractA design case study featuring a disk brake design for large earth-moving trucks wasimplemented in a senior (4th) year mechanical engineering design course at the University ofWaterloo. The case study was given to one class of 35 students in the spring term of 2009 andthen to a second class of 27 students in the spring term of 2010. The case study was given as anin-class exercise over two lecture periods.The design case study was designed and written in collaboration with an industry partner,Hitachi Construction Truck Manufacturing Limited located in Guelph, Ontario, Canada. Thecase study’s primary learning objective was for students to design the front disk brakes of a mid-range model truck while working in teams of about 5 persons. The implementation method hadthe students design the brakes after a lecture on disk brakes and using information given in thetext. They were then asked to design the brakes using information provided by a commercialmanufacturer and supplier of brake calipers. Students were asked to present their designs assketches on the board. A class discussion then followed. The brake design was unique in thatthe actual solution required the use of more than one caliper per disk.A survey given was to the students immediately after the case study exercise. The results of bothimplementations revealed that 95 % of the 40 respondents agreed or strongly agreed that the casestudy was an engaging application while 75 % perceived that it improved their understanding ofthe concepts taught. Approximately 60% of respondents agreed or strongly agreed that groupdiscussions helped their understanding of the concepts taught. About 80% of respondents agreedor strongly agreed that classroom discussions helped their understanding of the concepts taught.The survey also asked the students to express what they especially liked/disliked about the casestudy, what they would suggest to improve the case study and what advantages the case studyhad over traditional lectures. Students reported that they enjoyed the real life application of thetheory but also reported having difficulty with the open-endedness, lack of complete informationand lack of time provided to do the case study.

Nespoli, O. G., & Tempelman, H., & Spencer, R., & Lambert, S. (2011, June), Disk Brake Design Case Study Implementation Method and Student Survey Results Paper presented at 2011 ASEE Annual Conference & Exposition, Vancouver, BC. 10.18260/1-2--17786

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