Brakes:

1.1 Pressure Calculations:

Input Force = Driver Force × Pedal ratio
= 500 × 5
= 2500 N

Input force = force transmitted to master cylinder

Therefore, force transmitted to master cylinder = 2500 N
2
π×𝑑
Area of master cylinder = A = 4
2
π × (15.875)
= 4

= 197.93 mm2
Therefore, A = 197.93 mm2
Force transmitted at single Master cylinder =
𝐹𝑜𝑟𝑐𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑 𝑜𝑛 𝑡ℎ𝑒 𝑚𝑎𝑠𝑡𝑒𝑟 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟𝑠
2
… (At 50-50 Biasing)

2500
= 2

= 1250 N
Hence,
𝐹𝑜𝑟𝑐𝑒 𝑒𝑥𝑒𝑟𝑡𝑒𝑑 𝑜𝑛 𝑎 𝑠𝑖𝑛𝑔𝑙𝑒 𝑚𝑎𝑠𝑡𝑒𝑟 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟
Pressure in the brake lines = 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑚𝑎𝑠𝑡𝑒𝑟 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟
1250
Pressure in the brake lines = 197.93
= 6.315 N/mm

For 60:40 Biasing,

Force transmitted at Front Master cylinder = Force exerted on master cylinders*0.6
= 2500 * 0.6
= 1500 N
𝐹𝑜𝑟𝑐𝑒 𝑒𝑥𝑒𝑟𝑡𝑒𝑑 𝑜𝑛 𝑎 𝑓𝑟𝑜𝑛𝑡 𝑚𝑎𝑠𝑡𝑒𝑟 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟
Pressure in the brake lines = 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑚𝑎𝑠𝑡𝑒𝑟 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟
1500
Pressure in the brake lines = 197.93
= 7.57 N/mm

Force transmitted at Rear Master cylinder = Force exerted on master cylinders*0.4

= 2500 * 0.4
= 1000 N

𝐹𝑜𝑟𝑐𝑒 𝑒𝑥𝑒𝑟𝑡𝑒𝑑 𝑜𝑛 𝑎 𝑓𝑟𝑜𝑛𝑡 𝑚𝑎𝑠𝑡𝑒𝑟 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟

Pressure in the brake lines = 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑚𝑎𝑠𝑡𝑒𝑟 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟
1000
Pressure in the brake lines = 197.93
= 5.05 N/mm
1.2 Weight Transfer Calculations:

Mass of the vehicle (along with the driver) = 300 kg

Weight of the vehicle = Mass of the vehicle * g = 300 * 9.81 = 2,943 N

C.G. height of the vehicle = 266.7 mm = 0.2667 m

Wheelbase length = 1525 mm = 1.525 m

Static weight distribution: 40:60

Therefore,

Static Mass on front =300*0.4= 135 kg

Deceleration = 1.2 g
𝐷𝑒𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛 *𝑀𝑎𝑠𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑣𝑒ℎ𝑖𝑐𝑙𝑒 *𝐶.𝐺. ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑣𝑒ℎ𝑖𝑐𝑙𝑒
Weight transfer = 𝑊ℎ𝑒𝑒𝑙𝑏𝑎𝑠𝑒 𝑙𝑒𝑛𝑔𝑡ℎ

1.2*300*0.2667
= 1.525
= 53.58 kg

For dynamic load at 1.2 g braking:

Dynamic load on Front (Nf) = Static Mass on the front +Weight transfer
= 135 + 53.58
= 188.58 kg
= 1,849.9698 N
Dynamic load on Rear (Nr) = Static Mass on the rear - Weight Transfer
= 135 – 53.58
= 81.42 kg
= 798.7302 N

Thus, dynamic weight distribution at 1.2 g is:

𝐷𝑦𝑛𝑎𝑚𝑖𝑐 𝐿𝑜𝑎𝑑 𝑜𝑛 𝑓𝑟𝑜𝑛𝑡
Front (%) = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑣𝑒ℎ𝑖𝑐𝑙𝑒
x 100

188.58
= 300
x 100

= 62.86%
𝐷𝑦𝑛𝑎𝑚𝑖𝑐 𝐿𝑜𝑎𝑑 𝑜𝑛 𝑅𝑒𝑎𝑟
Rear (%) = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑣𝑒ℎ𝑖𝑐𝑙𝑒
x 100

81.42
= 300
x 100
 = 27.14%

1.3 Frictional Force Calculations:

Frictional force = µ * N

Coefficient of friction between road and tire = 1.7

Front wheel frictional force = Coeff. of friction between road and tire(µ) × Dynamic Load on
front

= 1.7 × 1,849.96
= 3,144.932 N
Rear wheel frictional force = Coeff. of friction between road and tire (µ) × Dynamic Load on
rear
= 1.7 × 798.73
= 1,357.841 N

1.4 Wheel Torque Calculations:

Wheel torque = Force * radius

Radius of the tire = 0.254 m = 254 mm

For torque on front wheels = Front wheel frictional force × radius of the tire

= 3,144.932 × 0.254

= 798.81 N-m
𝑇𝑜𝑟𝑞𝑢𝑒 𝑜𝑛 𝑓𝑟𝑜𝑛𝑡 𝑤ℎ𝑒𝑒𝑙𝑠
For torque on single front wheel = 2

798.81
= 2

= 399.405 N-m

For torque on Rear wheels = Rear wheel frictional force × radius of the tire

= 1,357.841 × 0.254

= 344.89 N-m
𝑇𝑜𝑟𝑞𝑢𝑒 𝑜𝑛 𝑅𝑒𝑎𝑟 𝑤ℎ𝑒𝑒𝑙𝑠
For torque on single Rear wheel = 2

344.89
= 2

= 172.445 N-m
1.5 Torque Due to Rotor Calculations:

Front Calliper Piston radius(r1) = 15.875 mm

Rear Calliper Piston radius(r2) = 12.7 mm

For 60:40 Biasing,

Pressure on front master cylinder = 7.57 N/mm2 (Calculated above)
Pressure on rear master cylinder = 5.05 N/mm2 (Calculated above)

Front Calliper Piston Area = 3.14 x (r1)2

= 3.14 * (15.875) 2

= 791.32 mm2
Rear Calliper Piston Area = 3.14 x (r2)2
= 3.14 * (12.7)2
= 506.45 mm2

Force on the front calliper = Pressure on front master cylinder * Area of front calliper Piston
= 7.57 * 791.32

= 5,990.2924 N

Force on the rear calliper = Pressure on front master cylinder * Area of rear calliper Piston
= 5.05 * 506.45

= 2,557.5725 N

Clamp Force on front callipers = Force on front callipers *2

= 5,990.2924 * 2
= 11,980.5848 N

Clamp Force on rear callipers = Force on rear callipers *2

= 2,557.5725 * 2
= 5,115.145 N

Coefficient of friction of brake pads = 0.4

Friction force generated by the pads (front) = Clamp force on front callipers * Coefficient of
friction of brake pads
= 11,980.5848 * 0.4
= 4,792.23 N
Friction force generated by the pads (rear) = Clamp force on front callipers * Coefficient of
friction of brake pads
= 5,115.145 * 0.4
= 2,046.058 N
Front Rotor:

Outer Diameter of the rotor (OD) = 175 mm

Inner Diameter of the rotor (ID) = 115 mm
175+115
Effective diameter of the rotor = 2
= 145 mm
 𝐸𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑟𝑜𝑡𝑜𝑟
Effective radius of the rotor = 2
= 72.5 mm

Torque due to front rotor = Friction force generated by the pads (front) * Effective radius of
the rotor
= 4,792.23 * 72.5
= 347.43 N-m
Rear Rotor:
Outer Diameter of the rotor (OD) = 181 mm
Inner Diameter of the rotor (ID) = 130 mm
181+130
Effective diameter of the rotor = 2
= 155 mm
𝐸𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑟𝑜𝑡𝑜𝑟
Effective radius of the rotor = 2
= 77.5 mm
Torque due to rear rotor = Friction force generated by the pads (rear) * Effective radius of the
rotor
= 2,046.058 * 77.5
= 158.56 N-m

1.6 Torsion spring calculations:

Outer Diameter (OD) = 12 mm Inner Diameter (ID) = 8 mm
𝑂𝐷
Mean Diameter (D) = 𝐼𝐷
= 10 mm
Number of active coils (n) = 5.25 (90˚ free position)
Diameter of spring wire (d) = 2 mm
Young’s Modulus (E) = 30 x 106 psi = 206842.7 N/mm2
𝐷
Spring Index = 𝑎 = 5

Leg 1 length (y) = 70 mm

Leg 2 length = 16 mm
4𝑐+1 0.615
Wahl Correction Factor = 4𝑐−4
+ 𝐶
= 1.3105

𝐸*𝑑4
Spring Rate/Spring constant = 𝐼𝐷10.8*𝐷*𝑛

= 5836.8 N-mm/360 degrees

Rate per degree = 16.213 N-mm/degree

Material Used: Music Wire ASTM A228
Material Shear Modulus = 10 x 106 psi = 68947.5 N/mm2