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Braking System: Design Report of Braking Brakes
Braking System: Design Report of Braking Brakes
Specifications
Pedal ratio = 6.2:1
Pedal size = 7.75
Braking percentage = 66:34
Master cylinder type: dual master cylinder fabricated by using two master cylinders and a
balance bar.
Master cylinder bore size = 1
Brake fluid: DOT-4
Brake lines: maruti 800 brake lines and hoses
Caliper type: single piston floating-type calipers
Caliper cup size = 1.5
Rotor type: solid
Rotor size = 8.5
Rotor thickness = 10mm
CALCULATIONS
1. BRAKES APPLIED TO ALL FOUR WHEELS
Time
t = 1.41 seconds
TOPPLING AT ACCELERATION AND DECELERATION
When brakes are applied, due to deceleration weight transfer of vehicle occurs and it
develops a tendency to topple about front wheels. The deceleration at which Rr becomes
zero and vehicle starts toppling is given by
ft = g ( cos * (b-l)/h sin )
The vehicle will have tendency to topple during braking while coming down of an
inclination.
For = 30,
ft = 13.1m/s2
And actual deceleration that will be produced at = 30,
f = 1.89m/s2
This deceleration is very smaller than ft = 18.74m/s2 at = 30. Hence, vehicle will not
topple at the event of braking.
When vehicle is accelerated, weight transfer of vehicle occurs and it develops a tendency
to topple about rear wheels. The acceleration at which Rf becomes zero and vehicle starts
toppling is given by
a = g ((l/h)* cos sin )
The vehicle will have tendency to topple during braking while going up of an inclination.
For inclination = 30
a = 10.01m/s2
This acceleration is far greater than our vehicles max achievable acceleration. So the
vehicle will not topple.
http://msis.jsc.nasa.gov/sections/section04.htm
Here we have to determine the values of pedal ratio and master cylinder bore size. Brake
rotors and calipers are already decided. They are going to be of Maruti 800 car.
Pedal force = 400N (from above figure)
Pedal ratio = p
Master cylinder bore size = dmc
Caliper cup size = 1.5
Weight of vehicle = 350g N
Radius of tire = 12.5
Coefficient of friction between road and tire = 0.8
Coefficient of friction between rotor and pads = 0.45
Diameter of rotor = 8.5
Effective radius of rotor = 3.5
Assuming front axle and rear axle reactions are equal and the brake percentage required
is 50:50. This has been assumed just for calculations as any other assumptions will not
affect the answer.
Torque on a single wheel, when skidding will start , T = 0.8*350g*12.5*0.0254/4 = 218
Nm
Pedal force applied = 400N
7/8
1
1
Pedal ratio
3.5:1
4.7:1
6.1:1
6.2:1