Design methodology:

The objective of the braking system is to provide a reliable and prompt deceleration for the vehicle. Moreover,
the driver must have complete control of the vehicle while the brakes are activated. More importantly, the brakes
must be capable of locking up all four wheels while on the pavement, which is one of the requirements stated by
the BAJA SAE rules. According to our calculation of the clamp force requirement and the brake available in the
market we have we decided to use the disc brake in all four wheel i.e front and rear. The selectivity includes
cost and availability of the brake.

Braking system design:

Brake considerations:
This year we are incorporating all wheel with disc brakes. Previous year we opted for disc brake in front wheel
& drum brakes in rear wheel.

Combination of brakes:
We are using disc brakes in both front and rear because it provides more efficient braking and according to our
requirement.
According to dynamic force distribution 60% weight is on front side and 40% on rear side during
braking. So disc brake in all four wheel will serve our purpose.
Maintaining brake balance under different situations such as normal, and very heavy brake use. Disc
brakes also lend themselves to being more effective .Reduces upspring mass
Since more dynamic frictional force is required on front wheels so disc brake will be very useful.
The drum brake has only one surface to dissipate the energy - the disc has two surfaces. Less weight of disc
brake increases steering ability as there is less inertia.

Brake
Disc brake
(front and rear wheel)

Company
bajaj pulsar 220 F(rear)

Hydraulic system
The brakes hydraulic system is controlled by single brake pedal, locking all the wheels at a
time.We are using OEM master cylinder for actuation of brake fluid.We have the pedal ratio
of 6:1. This is done to meet our braking requirement.
The brake fluid which we are using this time is DOT 3 .It is widely recommended, it is
effective as well as economical.

Brakes calculation:
GIVEN :

Diameter of master cylinder=3/4 inch=0.75 inch= 0.01905 m

Coefficient of Friction between pad and rotor () = 0.35.
Coefficient of friction between new tire and good road (1) = 0.8.

Diameter of caliper piston (Dc) = 1 inch= 0.0254 m.

Total weight of car (m) = 350 kg.
Acceleration due to gravity (g) = 9.81 m/s2.
Radius of tire (R) = 12 inch= 0.304 m.

BRAKE CALCULATIONS:

P = Tubing pressure.
F = Force on biasing bar.
A = Area of master cylinder.
A1 =Area of caliper piston
F1 = Clamping force on rotor.
= Coefficient of friction between pad and rotor.
N = Normal force on rotor.
1 = Coefficient of friction between new tire and good road.
Fr = Frictional force on tire.
N1 = Normal force on tire.
Re = Effective radius of caliper.
Tr = Braking torque.
Re = Effective radius of caliper.
Rr = Radius of rotor.
Ad = Deceleration of car.
Aa = Average deceleration of car.
V = Velocity of the car.
St = Total distance travel by vehicle.
T = Total time taken by the vehicle to stop.

Let the pedal ratio be 6:1

Consider the force applied on pedal be 100lb =444.82216 newton
Therefore force on biasing bar = 100*6=2668.93297 newton = 600 lb
Diameter of master cylinder = 0.75 inch = 0.01905m
Therefore area of master cylinder = (*(0.01905) 2)/4=0.00028496 sq. meter= 0.4417 square inch
Tubing pressure (P) = F/A= (2668.93297/0.00028496) = 9363904.63189N/m2 = 1358.122 PSI.

Frictional force on rotor (F1) =2N

N=Normal force on rotor(Clamping force) = (P*A1)

Therefore F1= (2**P*A1)

F1=2*0.35*9363904.632*((*0.0254^2)/4)
F1 = 3321.04226 newtons=746.6666 lb

The value of coefficient between new tire and good road surface is 0.8.
So friction force on tire (Fr) = (1*N1).

Dynamic weight on the front axle is 60% of the total force.

Consider total weight of vehicle=350kg.
Weight on front axle= 0.6*350= 210 kg.
Weight on one tire = 105kg.
Therefore the normal force on the tire (N1) = 105*g=1030.05N.

Braking torque = Fr*R

Tr = 0.8*105*9.81*12 = 0.304880.8*824.04N = 251.233Nm= 2223.01872 lb.

Braking torque due to friction on tire = Braking Torque produce by clamping force on rotor.
Therefore F1*Re = Tr.
Re = (251.233/3321.04226 ) =0.07564 m = 2.97725 inch.
Radius of rotor (Rr ) = Re+ radius of caliper =Re+0.5Dc
=0.07564+(0.5*0.0254)
Rr =0.0883223 m =88.3223 mm=8.83223 cm=3.47725 inch.

Rr=88.3223 mm
Diameter of rotor = 176.4468 mm.

For mean fully developed deceleration (MFDD)

Frictional force or Braking force = Inertia force.

1*N = m*ad
N=mg
0.8*m*g = m*ad
: ad = 0.8g

Therefore ad= 7.848 = 0.8g.

But taking reaction time the average deceleration becomes
ad= (V/ ((V/Ad) + 0.3g)).
Speed of the vehicle in top gear is 16.6667 m/s.
ad = 16.667/ ((16.667/0.8) + 0.3g)
=0.7009788 m/s2.

STOPING DISTANCE:
V2-U2=2(Aa) S.
S=V2/2(Aa) = (16.667)2/ (2*0.7*9.81)
S= 20.1975 m [Breaking distance]
Reaction time+build up time+perception= 0.8 s.
Therefore total distance travel by vehicle in this time is
Se= 16.667*0.8= 13.336 m.
Therefore total distance (St) = S+Se
=33.5335m.

TIME CALCULATION:
V=U+ (Aa)*t
t= 16.667/ (0.701*9.81) = 2.42408 s.
Total time taken to stop the vehicle after seeing the danger
T=t+0.8 s
T=3.2240 s.

Thermal calculation
T amb =ambient temperature=300 k
Q =flux produced in disc rotor (W/m2)
T max =maximum temp. attained by rotor=300 k
Arotor= area of rotor
Disc rotor is of gray cast iron hence value of following :D rotor =density of disc rotor = 7250 kg/m3
C =brake disc specific heat capacity = 460 J/kg/k
K=brake disc thermal conductivity = 57 W/(m k)
Ffriction= 3321.04226 N =746.6666 lb
This friction force is acting from both side of rotor hence Ffriction on one side
Ffriction1= 3321.04226/2 = 1660.5211 N
Power (P) = Ffriction1 * V =1660.5211 * 16.67
P = 27680.88724W

Flux (Q) =P/ Arotor

Arotor = *(0.12 0.072) =0.016022 m2
Q =27680.88724/0.016022 = 1.72765 * 106 W/m2

Using fourier law we get the formula to calculate the max. temperature of rotor
is
T max=(0.527 * Q * t0.5) / ( D rotor * C * K)0.5 + T amb

=402.727 K
Heat analysis of disc brake