Brake Design Calculation

Steps involved in brake system design

Calculation
of Pedal
Force Ratio.
required at
Calculating master
required cylinder
Calculating pressure
Braking
Calculating Force
stopping time
Calculating
required
deceleration
Assumptions

 Initial velocity = 60 kmph = 16.667 m/s

 Stopping distance= 10m

 Mass of the vehicle = 250 kg

 Tire diameter = 24 inches = 0.6096 m

 Diameter of the disc = 200mm = 0.2m

 Diameter of calliper piston = 27.5mm = 0.0275m

 Diameter of Master cylinder piston = 18mm = 0.018m

Calculating the deceleration
 Using third equation of motion,

 Where,
V = Final velocity(m/s)
U = Initial velocity(m/s)
a = Acceleration(m/s2)
S = Stopping distance(m)

 Considering stopping distance to be S = 10m ,

 Therefore,

 Since the calculated value is negative, the acceleration here is acting in the opposite direction of vehicle
motion. This acceleration is called deceleration.
Calculating Stopping time
 Using first equation of motion,

 Where,
a = deceleration (m/s2)
t = Stopping time(s)
 By substituting the value in above equation,

 The time calculated here is the time required for the vehicle to stop after the brakes are applied. But in real life
scenarios the actual stopping time is given by,

 Where,
ti = Immediate reaction time (0.06s)
ta = Application time or the time required to apply the brakes(0.18s)
tb =Time required to decelerate the vehicle from its acceleration(0.95s)
Calculation of Braking Force

 In case of braking the kinetic energy of vehicle is
converted/lost into the heat energy.
 The difference in the kinetic energy is given by,
 As per the law of conservation of energy, ‘Energy
can neither be created nor destroyed’. Which means
the kinetic energy is converted to heat energy.
 Therefore,

 Similarly at the time of braking the work done is given by

the product of thr frictional force acting against vehicles
motion and the stopping distance.  That makes braking force to be,
 Therefore,

 Where,
W = Work done in stopping the vehicle
S = Stopping distance of vehicle after brakes is applied
FB = Braking force needed to stop the vehicle completely.
Calculating the required pressure in the braking system

 The braking torque required at the wheel is given  The Pressure required in the brake system is given
by, by,

 Therefore,
 Since the wheel and disc are rigidly connected the
braking torque required at the disc will be the
same. Which is given by,
 The pressure required in the braking system is,

 Where is the coefficient of friction between disc

and brake pad.
 The force required on the disc = 11758.44 N
Calculation required force at master cylinder

 According to Pascal's law the pressure in the closed system will be same, hence the pressure need in the
caliper should be generated force provided by the pedal to the master cylinder.
 Thus the force required at the master cylinder,

 Therefore the force required at the master cylinder is,

 But as per a various studies the human leg can apply a force of 700N with ease.
Calculation of Pedal Ratio

 In such cases were the required force is more than the force that a human can apply,
we take the mechanical advantage of the pedal.
 The brake pedal is basically a 2nd order lever. With the length of load arm(Y) and the
length of effort arm(X).
 The ratio of these length is known as the pedal ratio.
 This can be calculated using required mechanical advantage, in this case to exert a
force of 2518.73N using the force of human leg 700N.
 Therefore,

 The pedal ratio can be kept as 4 to assure safe working of the braking system.
Review

 Calculating the deceleration required

 Calculating the Stopping Time

 Calculating the Braking Force

 Calculating the required pressure

 Calculating the force required at master cylinder

 Calculating the pedal ratio

Thank you…

 Keep learning.
 Keep exploring.