The basic objective was to design a hydraulic brake system capable of locking all four wheels

simultaneously. The design procedure was initiated by calculating the optimum braking force
required to lock all four wheels at different deceleration values. The calculations were carried out for
required braking force at different values of applied force. The calculations were repeated for all the
combinations of master cylinder piston area and caliper piston area available to us. The normalised
values of optimum and generated braking force were plotted and analysed to select the desired
hardware combination.

The pedal geometry was finalised after hardware selection, keeping in mind the required mechanical
leverage for driver comfort and proper locking of wheels. The pedals were designed and optimised
with the help of FEA simulations. Aluminium 7075-T6 was the material chosen for the brake, clutch
and throttle pedals, the reason being its high yield strength/weight ratio, high fatigue strength and
high stiffness values. For adjustability according to the driver, pedal pad was bolted to each pedal
which can translate, providing a wide range of driver seating positions. AP Racing CP7855 bearing
mounted master cylinders with a bore size of 15.9 mm for front and 20.6 mm for rear circuit are
used to generate the required brake pressure. Tilton 600 series balance bar allows for the brake
bias adjustments, maximum of which is limited to around 70:30. Outboard, custom floating rotors
with outer diameter of 200 mm and thickness 4 mm was designed and further structurally optimised
by performing thermal and multi stop simulations through FEA. Stainless Steel 420 was chosen as
the material for rotors because of its high thermal conductivity, low Coefficient of thermal expansion
and high wear resistance. Due to compatibility with rotor diameter and thickness, further supported
by brakes calculation Wilwood GP200 fixed type calipers were selected having dual piston with
piston area of 793.55 mm2 for both front and rear. Due to its easy availability and working
temperature DOT 3 brake fluid having dry boiling point of 205C and wet boiling point of 140C was
chosen for hydraulic actuation.
The designed hydraulic brake system is validated by testing and data acquisition. Rotor temperature
will be recorded and compared by using thermocouple probe after a test run.