SEMINAR REPORT ON

DISC BRAKE

Submitted by :
Bhola kumbhakar
MECHANICAL ENGG.
Regd. No. : 0401227322
Principle of Brake
AISHWARIA BACHHAN
How Brakes Work
•
Drum Brake Assembly
 Drawbacks of Drum Brake
• Worn drum and shoes

• Can cause unreliable stopping

• Excessive pedal effort

• Brake pedal pulsation

Introduction to Disc Brake
 What is Disc Brake means?
• A disc brake is a device used for slowing or
stopping the rotation of a wheel. A disc brake
usually made up of cast iron or ceramic is
connected to the wheel or the axle.
• To stop the wheel, friction material I n the
form of brake pads is forced mechanically,
hydraulically or electromagnetically against
both sides of the disc. Friction causes the disc
and attach wheel to slow or stop.
 Components of Disc Brake
• The brake pads

• The caliper, which contains a piston

• The rotor, which is mounted to the hub

 Working principle : -
• Though disc brakes rely on the same basic
principles to slow a vehicle (friction and heat),
their design is far superior to that of drum
brakes. Instead of housing the major components
within a metal drum, disc brakes use a slim rotor
and small caliper to halt wheel movement.
Within the caliper are two brake pads, one on
each side of the rotor, that clamp together when
the brake pedal is pressed. Once again, fluid is
used to transfer the movement of the brake
pedal into the movement of the brake pads.
DISC BRAKE ASSEMBLY
 Mechanism of Assembly
Because a disc brake assembly can absorb more heat
than a drum brake assembly, most cars use disc
brakes for their front brake systems. When the brake
pedal is pushed, brake fluid from the master cylinder
compresses the brake pads against the rotors
attached to the vehicle's front wheels. The friction
between the stationary pads and the revolving rotors
causes the rotors and wheel to slow and stop.
Full assembly
 Working Principles of Assembly
• There are three basic components making up disc brakes: the
rotor, the brake pads, and the calipers. The rotor is a circular
metal disc that is mounted behind your tire to the hub. Next
are the calipers. Picture a circus performer who can spin a
dinner plate on the tip of his finger. To stop the plate from
spinning, he uses his fingers to clamp down on the plate. The
rotor is similar to the plate, and the fingers act similarly to the
calipers. At the tips of the fingers would be the brake pads,
which are made of a softer material than the rotor in order to
keep it free from surface damage. When you apply pressure
to the brake pedal, you are squeezing the fingers onto the
plate, or the calipers onto the rotor.
 Function of Break Pedal
• How is the energy from the brake pedal passed onto the
calipers? There is hydraulic fluid, which is a type of oil,
running within a set of lines. These lines are your brakes lines
that connect to the piston within the calipers. When
actuated, the pressure from the compressing hydraulic fluid
causes a piston with a brake pad on one end of the calipers to
move outward, and a brake pad on the other end of the
caliper to move similarly, squeezing the rotor. Enough friction
is created to slow the rotation of the rotor, and therefore the
wheels, to bring the automobile to a safe, controlled stop.
Disc brake of Car
 Disc brake of Bike

(Front Wheel) (Rear Wheel)

Vented disc brakes have a set of vanes, between the
two sides of the disc, that pumps air through the disc to
provide cooling.

Disc brake vents

 Self Adjusting Brake
• The single-piston floating-caliper disc brake is self-
centering and self-adjusting. The caliper is able to slide
from side to side so it will move to the center each time the
brakes are applied. Also, since there is no spring to pull the
pads away from the disc, the pads always stay in light
contact with the rotor (the rubber piston seal and any
wobble in the rotor may actually pull the pads a small
distance away from the rotor). This is important because
the pistons in the brakes are much larger in diameter than
the ones in the master cylinder. If the brake pistons
retracted into their cylinders, it might take several
applications of the brake pedal to pump enough fluid into
the brake cylinder to engage the brake pads.
 
 Self Adjusting Disc Brake
• Older cars had dual or four-piston fixed-
caliper designs. A piston (or two) on each side
of the rotor pushed the pad on that side. This
design has been largely eliminated because
single-piston designs are cheaper and more
reliable.
Servicing Your Brakes
The most common type of service required for brakes is changing
the pads. Disc brake pads usually have a piece of metal on them
called a wear indicator.

Photo courtesy of a local Autozone store

Disc brake pad
When enough of the friction material is worn
away, the wear indicator will contact the
disc and make a squealing sound. This
means it is time for new brake pads.

There is also an inspection opening in the

caliper so you can see how much friction
material is left on your brake pads.
 Advantages of Disc Brake
• I. Power
• Disc brakes have a “power” advantage over rim brakes in two ways:  First, disc
brakes (mechanical or hydraulic) are able to generate much higher clamp forces
than rim brakes.  Second, the interface between the brake pads and the rotor can
be customized for maximum brake system performance.
• II. Environmental Consistency
• Disc brakes are made to thrive in harsh environments.  Disc brakes are located at
the center of the wheel, and are thereby much more protected from the
environment.  Water, Mud, etc need to be splashed up on to the rotor or caliper
to affect the braking surface.  Also, friction materials can be designed to
specifically remove water from the braking surface such that performance is not
affected.  These types of materials are not realistic for rims and rim brakes. Disc
brake rotor materials can withstand the aggressive nature of the pads.
• III. Location
• In addition to the protection from the environment, the location of the brake
systems at the center of the wheel prevents out of true wheels from affecting the
setup or performance of disc brakes.
 Extra Features
• Same braking wet or dry
• Rims last longer
• Tire sidewalls stay clean and last longer
• No brake pad tire cuts!
• Disc will never wear out! Not in your lifetime.
• Run with an out of true wheel, even a bent spoke!
Get it fixed soon, though.
• Less hand pressure required at the brake lever.
Various Application

(Multiple Disc Brake)

Wheel with Disc Brake
Disc Brake with Suspension
Bicycle with Disc Brake
Scooter with Disc Brake
Disc Brake of Bus
Disc Brake of Train