MANUFACTURE AND WORKING OF

CERAMIC BRAKE SYSTEM

-BY

VIKASH PANDEY
18JJ1A0345
MECHANICAL

UNDER THE GUIDANCE OF

DR.SURESH ARJULA
ASSISTANT PROFESSOR OF ME
Introduction
 Today’s technology is in need for speed, also safety as well,
for that deceleration is needed engines of max efficiency for
maintaining the speed & brakes of latest technology is
used.
 Brake system are required to stop the vehicle within the
smallest possible distance. By converting kinetic energy
into heat energy which is dissipated to atmosphere.
MAIN REQUIREMENTS

 Brakes must be strong enough to stop the vehicle within the possible
distance in an emergency. (safety)
 Brakes should have good antifade characteristics also on constant
prolonged application its effectiveness should not decrease.
STOPPING DISTANCE OF A VECHILE DEPENDS

 Condition of road surface.

 Condition of tire thread.
 Coefficient of friction b/w tire thread & road surface.
 Coefficient of friction b/w brake disc/drum & brake pad.
 Braking force applied by the driver.
TYPES OF BRAKES
According to the purpose
• Service or primary brakes
• Parking or secondary brakes

According to the construction

• Drum brakes
• Disc brakes

According to the method of actuation

• Mechanical brakes
• Hydraulic brakes and air brakes
• Electric brakes
• Vacuum brakes

According to the extra braking efforts

• Servo brakes or power assisted brakes
• Power operated brakes
DISC BRAKE- CONSTRUCTION
TYPES OF BRAKE MATERIALS
Grey cast iron disc
• Heavy
• Rust formation

Aluminum disc
• Light
• Less resistant to heat and fade

Carbon- fiber disc

• Heat resistant
• Needs high working temperature

Ceramic disc
• Inorganic and non-metallic
• Hard and brittle material
• High heat and abrasive resistant
• Can sustain large compressive load
COMPARISON b/w CERAMIC DISC BRAKES
AND CONVENTIONAL DISC BRAKES

 Grey cast iron disc is heavy which reduces acceleration uses more
fuel and has high gyroscopic effect.
 Ceramic disc brake weight less than carbon/carbon disc but have
same frictional values, used in Formula1 racing cars etc.
 CDB good at wet conditions but carbon/ carbon disc fails in wet
conditions.
 Weight – CDB are 61% lighter, reduces 20kg of car, apart we can
save the fuel, resulting in better mileage. We can add more safety
features instead of the current weight.
MANUFACTURE OF CERAMIC DISC BRAKE

 In earlier days disc brakes were made from conventional brittle ceramic material.
 DIAMLER CHRYSLER made carbon fibre reinforce brake disc to avoid the
brittle property. short carbon fibres + carbon powder + resin mix(at1000ᴼ c,
sintering) = stable carbon frame work.
 After cooling ground like wood brake disc obtains its shape.
 Add silicon to the required shape and insert in the furnace for the second time.
 Resins : thermo plastics resins and thermo setting resins .
COATING OF CERAMIC ON
CONVENTIONAL BRAKE DISCS

 FRENO Ltd-used metal matrix composite for disc, an alloy of

aluminum for lightness and silicon carbides for strength. The
ceramic additive made the disc highly abrasive and gave a low
unstable Coeff. of friction.
 SULZER METCO Ltd- special ceramic coating, developed thermal
spray technology as well as manufacturing plasma surface.
PORSCHE CERAMIC DISC BRAKES (PCCB)

 This is manufactured using

a high vacuum process.
 The process involves
heating carbon powder,
resins and carbon fibres in
a furnace at 1700ᴼc.
Properties of PCCB

 CDB with the involute cooling ducts for an efficient cooling

 Offers braking response, fading stability, less weight and service
life.
 PCCB ensures maximum deceleration without any particular
pressure on the disc brakes.
 Superior response under wet conditions
 Cross drilled brake discs help to optimize response of the brakes
also in wet weather.
 Advantages
 50% lighter than metal disc brakes reduces 20kg of car. In the case of train 36
disc brakes saving amount to 6 tons . Apart from saving fuel also reduce un-
sprung masses with a further improvement of shock absorber response.
 High frictional values in deceleration process Porsche- 100 to 0 km in 3 sec.
 Brake temperature resistance up to 2000 ᴼ c.
 Still runs after 300000 km need not change CDB.
 No wear, maintenance free and heat and rust resistant even under high oxygen
concentration.
 Heavy commercial can be braked safely over long distance without
maintenance.
 Disadvantages

High initial cost and high cost of production.

 Applications

 FORMULA1- in mid 90’s French sports car specialist Venturi.

 Porsche 911 turbo- with a top speed of 305 km/h and acceleration
from rest to 100 km/h in 4.2s. Its engine 3.6 L with 420 hp max
torque 560 Nm is still running with PCCB.
 911GT2- and Mercedes Benz’s futuristic vision GST is going to
reinforce CDB .
 Conclusion

CDB due to its advantages over the conventional brake

disc are going to be the brake disc for cars in the
future. With the success of Porsche turbo car, many
other racing cars and commercial vehicles are going to
implement CDB in cars.
Thank You