DESIGN AND ANALYSIS

OF BRAKES OF GO-KART

INTRODUCTION:

The main motive of undertaking this project of Design and

Analysis of Disc Brake of Go-Kart is to study and evaluate the
performance under severe braking conditions and there by
assist in disc rotor design and analysis. This study is of disc
brake used for Go-kart. SOLIDWORKS package is a dedicated
modeling package used for design the disc brake rotor.

BRAKE REQUIREMENTS:

The brakes must be strong enough to stop the vehicle with in

a minimum Distance in an emergency.
The driver must have proper control over the vehicle during
braking and the vehicle must not skid.
The brakes must have good anti-fade characteristics i.e. their
effectiveness should not decrease with constant prolonged
application.
The brakes should have good anti wear properties.

DISC BRAKE:

A disc brake consists of a cast iron disc bolted to the wheel hub
and a stationary housing called caliper.

The caliper is connected to some stationary part of the vehicle and

It containing a piston.

In between each piston and the disc, there is a friction pad held in
position by retaining pins, spring plates etc.

The passages are drilled in the caliper for the fluid to enter or leave
each housing.

These passages are also connected to another one for bleeding.

Each cylinder contains rubber-sealing ring between the cylinder

and piston.

PRINCIPLE:

A disk brake works on the principle of Pascals

Law/Principle of transmission of fluid pressure.

Pascals law which states that pressure at a point in a

fluid is equal in all directions in space. According to
this law when pressure is applied on a fluid it travels
equally in all directions so that uniform braking action
is applied on wheels.

The principle used is the applied force (pressure) acts

on the brake pads, which comes into contact with the
moving disc. At this point of time due to friction the
relative motion is constrained.

WORKING:
When the brakes are applied,
hydraulically actuated pistons move the friction
pads in to contact with the disc, applying equal and
opposite forces on the later. On releasing the brakes
the rubber-sealing ring acts as return spring and
retracts the pistons and the friction pads away from
the disc. The main components of the disc brake
systems are below:

The Brake pads

The caliper, which contains the piston

The Rotor, which is mounted to the hub

BRAKE FUNDAMENTALS:
As we decide to apply brake on rear two wheels of our go-kart and the
fundamentals of the brake are below:

STOPPING DISTANCE:
The distance a vehicle will travel
from the point when itsbrakesare fully applied to when it comes to a
complete stop.
BRAKEBALANCE:
The ratio of braking force distributed
between the front and rear wheels.
BRAKE FADE:
Brake fadeis a term used to describe
the partial or total loss ofbraking power used in a vehiclebrakesystem.

BRAKING TORQUE:

The brake torque is the moment

of braking force about the center of rotation.
BRAKE EFFICIENCY:
The brake efficiency is defined as the
braking force produced as a percentage of the total weight of
vehicle.
CLAMPING FORCE:
The force pressing each brake pad
against the disc is called as clamping force.

CALCULATION:
FUNDAMENTAL DATAS

VALUES

STOPPING DISTACE

1 METRE

BRAKING TIME

0.14 SECONDS

BRAKE BALANCE

450 NEWTON

BRAKE FORCE

1212 NEWTON

BRAKE FADE OR POWER ABSORBED

103 KILOWATT

CLAMPING FORCE

1515 NEWTON

BRAKE TORQUE

83 NEWTON METRE

PERCENT OF WEIGHT TRANSFER AT FRONT

30%

BRAKE EFFICIENCY

82%

MATERIAL SELECTION:
As we decide the aluminium as material for disc rotor
design, because of following factor

Less weight
Corrosion resistance
PROPERTIES

VALUES

ULTIMATE TENSILE
STRENGTH

310 Mpa

TENSILE YIELD
STRENGTH

276 Mpa

DENSITY

2700 Kg/m3

MODULUS OF
ELASTICITY

68.9 Gpa

POISSON RATIO

0.33

MODELING OF DISC ROTOR: