Design & Analysis of

Disc Brake System

presented by: yadava

 INTRODUCTION
Brake that operates by the action of a friction material
pressed against the sides of a rotating disc by caliper.
Brake system is safe of passengers and it is the most
important control system in modern cars. Due to brake
system is convert kinetic energy to heat and help in
friction. Friction force is increase the temperature of disc
which is in contact with pad. When heard press in brake
the temperature of disc may increase. Usually brake
system contains a cost iron disc bolted to wheel hub and
fixed housing named caliper. Caliper the brake system
provide such as stable operation within the entire load
range and the speed of service, that can help driver to
avoid accidents. Working of brake relies upon the
protection of essentialness.
The most commonly used brakes are frictional brakes, where
the grinding made between two articles convert the dynamic
essentialness of the moving vehicle into worm . In this project
we design the rotor of the disc.

Figure 5.1(disk)
 Working of disc brake system

When the brake pedal pressed in high pressure fluid from the master
cylinder pushed the piston outward. The piston pushes the brake pad
against the rotating disc. The inner brake pad touches rotor, the fluid
pressure exerts further force and the caliper moves inward and pulls
the outward brake pad towards the rotating disc and it touches the
disc. Now both the brake pads are pushes the rotating disc, a large
amount of friction is generated in between the pads and rotating disc
is slow down and vehicle finally let stop. When the brake pad is
released the piston moves inward the brake pad moves away from
the rotating disc and the vehicle again starts to move.
 Parts of break system

Break pedal
It is the parts of disc break in which force applied by
driver. Driver steps on activate the breaks when a pedal
press move the piston in master cylinder.

figure5:2(brake pedal)
Master cylinder

It is the parts of disc break by which force is converted into

pressure. Primary piston moves, which in turn pressurizes fluid
in front of the fist piston. The secondary piston and primary
piston are connected through a spring . As the primary piston
moves, it causes the secondary piston to move and pressurize
fluid in front of it.

Figure 5.3 (master cylinder)

Caliper

The brake caliper is the assembly which houses the brake pads
and pistons. The pistons are usually made of plastic, aluminum
or chrome-plated steel.
there are two types of caliper is fixed and floating

Figure 5.4(caliper)
Rotor

Rotors are metal discs supported by the suspension. The

calipers clamp on to them to slow their rotation, and then slow
or stop the vehicle. The rotor are made by cast iron or steel and
high end cars use a carbon ceramic rotor.

Figure5.5(rotor)
 Rotor pad

• Rotor pad is provided friction force when is contact with

rotor. Work to slow or stop vehicle. Rotor pad can made of
ceramics and other plastics, inhalation of brake dust
should still be avoided regardless of material.

Figure5.6(rotor pad)
 Modification
The disc brake includes rubbing surfaces with cooling vans. The
fist geometrical modification is mad by increasing the disc neck
thickness from 3mm to 5mm. The second is made on thickness
of the top-hat structure by increasing it from 5mm to 8mm. Both
the rotor modification pertain. Modification of the neck section
is also reasonably good where the unstable frequencies are
reduced to four with small positive real values changing the
coupling between the rotor and pad. By modifying the shape of
the brake pad has been found to be effective. The main purpose
of the pad slots is to alter the pad bending modal frequencies and
to provide a channel for the exit of debris and dust. Reduce the
weight is to use aluminum mourting bell and cast iron.
 Advantages of disc break

Disc break help to easily stop the vehicle.

It generates less heat.
The disk brake is easy to control.
It never skid in wet condition.
Greater braking power.
Longer life abrasive pads and disc.
The disc break increase the bike beauty.
 Disadvantages of disc break

The price is high.

Limited maintainability in field conditions.
High load spoke wheel set.
The disc is more susceptible to break noise.
Expensive as compared to drum brake.
To many components used in this brake so increases
weight.
 Types of disc

Normal disc
They have more surface area touching the pads. When the brakes are
applied so initially have better braking power. When a disc is heated
gas can be built between the pad and the disk. Which causes brake fade
and glazing.

Figure 5.7( normal disc)

 Drilled disc

The face of these disc are drilled all the way through mainly to
increase surface area. In this disc increase the surface to drill
the disc. Because heat is easy moving. The holes go slightly to
stop the gas buildup this causes the brake fade. The problem
with drilled discs is the may have tendency to start cracks and
collect dust and debris. In this disc is use to motorcycle.

Figure 5.8 (drilled disc)

 Grooved disc

The face of these discs hove diagonal lines cut into them, there are
two reasons for this. Firstly they allow the venting of brake pad
gasses thus eliminating brake fade. They also eject pad dust to stop
glazing of the pad. This keeps the pad face allowing better braking.
Dimpled disc
The dimples in a disc clear debris from the pad but the main reason
is to reduce weight. It use to vehicle.

Figure 5.10(dimpled disc)

 Types of disc brake

Swinging caliper disc brake

The caliper is hinge about a fulcrum pin and of the friction pin
and one of the friction pads is fixed to the caliper. The fluid
under pressure presses the outer pad against the disc to apply
the brake. The reaction on the caliper causes it move the fixed
pad. Slightly applying equal pressure to the other side of the
disc. The caliper automatically adjust its position by swinging
about pin.
 Sliding caliper disc brake

These are two piston between which the fluid under pressure
is sent which presses one friction pad directly. On to the disc
where as the other pad is passed indirectly via the caliper.
 Conclusion

Brake rotor assumes essential to be cautiously chosen verity

types of disc plate is use in disc brake system, and the parts of
brake and its procedure are explain this journal and I just
understand the how to work in brake system. Grey coast iron and
carbon-ceramic were selected as materials and application of disc
brake and it profit. I will just understand with advantages and
disadvantages of disc brake system.
Reference
THANKYOU