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Brake Rotor Materials

Properties
Material

Compres
sive
Strength
(MPa)

Coefficient
of friction

Grey Cast
Iron

1293

0.41

Ti-6Al-4V

1070

TMC

Wear Rate

Specific
Heat

Specific
Gravity

2.36

0.46

7.2

0.34

246.3

0.58

4.42

1300

0.31

8.19

0.51

4.68

AMC-1

406

0.35

3.25

0.98

2.7

AMC-2

761

0.44

2.91

0.92

2.8

(mm3/N)

After web -

Scaled Properties Properties Material Compressiv e strength Coefficie nt of friction Wear Rate Specifi c Heat Specifi c Gravit y Performan ce Index Rank GCI 99 93 100 47 38 75.4 2 Ti-6Al-4V 82 77 0.9 5 TMC 100 70 29 52 58 61.8 4 AMC-1 31 80 73 100 100 76.8 3 AMC-2 59 100 81 94 96 86 1 After web – Reference .96 59 61 55.

Brake Fluids Dry Boiling Fluid Type Point(ºc ) Wet Boiling Point(ºc) Primary Viscosi Constitue ty nts DOT2 190 140 DOT3 205 140 1500 DOT4 230 155 1800 DOT5 After web .Reference 3 260 180 900 Caster Oil/Alcohal Glycol Ether Glycol Ether Silicon .

15-PentaOxaHeptaDecane 1-Methoxy-2-(2-methoxyPropoxy)Propane .6.Dot4 Composition • • • • • Triethylene Glycol Tetraethylene Glycol Dibutoxy Tetraglycol 3.12.9.

61 After book – Reference Used in cranes.1 2.10 41. Used in marine.Brake Pad Materials Material Coefficie nt of friction (µ) Dynami Melting point c temp. pressur (°C) e (MPa) Other properties 0.41 1580 for barite PTFE Kevlar 0. copper.15 Mineral enhanced 0.36 0.36 326.10 brakes 3. 2.6 Above 500 In dry brakes In wet 0.22 3.85 chemically inert Good dimensional stability 0.7 Fades at 260 Greater fading at 370 Two types: woven & non woven Non abrasive to iron. industrial brakes and clutches.1-0. off road equipment. .05-0. hoists.

35 ROTOR APACHE RTR160(REAR ) 20*2. 855 DRILLED BRAKE FLUID - - - - DOT4 .7 2.3 G.I.59*0.=1.APACHE RTR DIA.PISTON 1.EXT.C.905 ALUMINIUM - TMC - 2150 DOUBLE PISTON CALIPER 1.=2.5 SEMI METALLIC 160 µ=0.Selected Parts PART NAME MASTER CYLINDER CALIPER BRAKE PAD MODEL NAME DIMENSIONS(c m) MATERIAL COST(Rs) SPECIFICATI ON - PISTON DIA. 160(FRONT) DIMENSION=10. 5*13.5*8 - 7*3.

• It is inserted in a jar containing brake fluid so that no more air bubbles can enter in fluid while bleeding. • Bleeding valve is connected with a plastic pipe. After web: Reference 5 .com .Brake Bleeding • Bleeding port is in the upright position as shown.by dummies.

Effective area of caliper piston = π/4*(0. Hydraulic pressure generated by master cylinder(Pmc)Effective area of master cylinder piston(Amc) = π/4*(0.98 MPa 3. Pedal ratio = 4:1 1.8487×10-4 m2 Now. Pmc= Pcal = 4.01905)2 m2 = 2. Hydraulic pressure transmitted to caliperAccording to Pascal’s law. of caliper pistons) = 1.027)2 *2 m2(where 2= no.75 N .Force acting on CaliperFcal = Pcal × Acal = 5699.98Mpa Now.Brake Calculations Force applies by the driver on brake pedal= 80lbs=355N (assumed).Force Output of brake pedal(Fbp) = 355*4 =1420N 2.14453 × 10-3 m 4. Pmc = Fbp /Amc = 4.

– 1/2* width of brake pad = 0.30 (coefficient of friction of brake pad material) 4. Braking Torque generated at Each Wheel(T single)Mean Effective Radius(MER)=Disc Radius. total braking force acting on both wheels. Ftotal = 2* Fsingle = 3863.138 Nm 5.1-0.58 N . Total Braking ForceFsingle = Tsingle/Rwheel = 1931.79 N We are using Two Disc Brakes so. of Brake Pads.3.) ‘µ’ =0.85 N where ‘n’ = 2 (No.175 =0.0825m Tsingle = FN* MER =282. Normal Force acting on rotors(F N)Fnormal = Fcal*µ*n =3419.

For velocity of 40km/hr t = V/a = 0.For velocity of 40km/hr S = V2/2a =2.Stopping Time(t). Deceleration(a)So.6. Stopping Distance(S).5177 sec . F = M*a a = F/M =21.875 m 8.46 m/s2 7.

Speed Vs Stopping Distance Stopping Distance(m) 16 14.47 6 4 2.8 8 6.56 14 12 11.49 50km/hr 60km/hr 70km/hr Speed(Km/hr) 80km/hr 90km/hr .5 10 8.88 2 0 40km/hr 4.

91 0.2 0 40km/hr 50km/hr 60km/hr 70km/hr Speed(Km/hr) 80km/hr 90km/hr .Speed vs Stopping Time Stopping Time(Sec) 1.78 0.8 0.65 0.4 0.2 1.04 1 0.6 0.16 1.4 1.52 0.

Reference 5.wiley.co.opieoils.References • Reference 1 -https ://www.co.org%2Fpublication%2FWCE2010%2FWCE2010_pp2322-23 pdf&usg=AFQjCNHVPEa6XUOlBI7JjoaafN2X9khj5A&sig2=YkwdkX356KUTcRwGBx81VA&bvm=bv.c2I • • • • Reference 3 .http://media.google.com/Lux/71/131171.uk/pdfs/techarticles/Brake-Fluid-Explained.in/url?sa=t&rct=j&q=&esrc=s&source=web&cd=1&cad=rja&uact=8&sqi=2&ved=0ahUKEwiGnd-Y86f NAhXLRY8KHdX_BYEQFggbMAA&url=http%3A%2F%2Fwww.http://www.org%2Fpublication%2FWCE2010%2FWCE2010_pp232 2326.co.d.google.d.c2I • Reference 2 https://www.124272578.124272578.pdf Reference 4 – Clutches And Brake Design And Selection by Willliam C Orthwein.jpg?h=400&w=527 .iaeng.pdf&usg=AFQjCNHVPEa6XUOlBI7JjoaafN2X9khj5A&sig2=YkwdkX356KUTcRwGBx81VA&bvm=bv.in/url?sa=t&rct=j&q=&esrc=s&source=web&cd=1&cad=rja&uact=8&sqi=2&ved=0ahUKEwiGnd -Y86fNAhXLRY8KHdX_BYEQFggbMAA&url=http%3A%2F%2Fwww.iaeng.image2.