ISSN(Online): 2319-8753

ISSN (Print): 2347-6710

International Journal of Innovative Research in Science,

Engineering and Technology
(A High Impact Factor, Monthly, Peer Reviewed Journal)
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Vol. 9, Issue 3, March 2020

Design, Development and Analysis of

Hydraulic Disc Brake System for Formula
Student Race Car
Prashant B.Shelar1, Rohit S. Patil2
Assistant Professor, Dept. of Mechanical Engineering, D.Y. Patil College of Engg. & Tech., Maharshtra, India1
SAE Member, Student, Dept. of Mechanical Engineering, D.Y. Patil College of Engg. & Tech., Maharashtra, India2

ABSTRACT: The main objective of this paper is design and development of hydraulic disc brake system for
FORMULA STUDENT race car. The research done is concentrated on working and effectiveness of mechanism and
design a system such as caliper selection, master cylinder selection and pedal assembly to obtain highly efficient
braking system for vehicle as per the requirements. The design process consists of first determining the braking
parameters and forces acting on each axle and analyze it. After analyzing and optimization of the geometry the entire
system is been manufactured. The braking system was designed to be lightweight and compact while still providing
adequate braking power for locking of all four wheels of the vehicle. The paper discusses the theory and basic design
criteria of the hydraulic disc braking system. The design obeys the rules stated by FSAE rulebook and FORMULA
BHARAT RULEBOOK 2019.

KEYWORDS: Braking system, Caliper Selection, Wheel locking, Braking power, Braking parameters.

I. INTRODUCTION

As buildup formula vehicle one of the main part is to design braking system. In compliance with good suspension
system, good handling, safe cornering, there is one most critical system which is braking system. Without braking
system n the vehicle will put driver in an unsafe position. The hydraulic disc brakes is an arrangement of braking
mechanism which uses brake fluid typically containing ethylene glycol, to transfer pressure from controlling
mechanism to the braking mechanism. Hydraulic brakes works on the principle of Pascal’s Law which states that
“Pressure at a point in a fluid is equal in all directions in confined space”. According to this law when pressure is
applied on fluid it travels equally in all directions so that uniform braking action is applied on all four wheels. The disc
brake is a wheel brake which slows rotation of the wheels by the friction caused by pressing brake pads against brake
disc with a set of calipers.

II. BRAKING SYSTEM METHODOLOGY

The braking system had to provide enough braking force to completely lock the wheels at the end of a specified
acceleration run, but remain small enough to fit inside of the front wheels and also prove to be cost effective. The
braking system was designed by first determining parameters necessary to produce a given deceleration, and
comparing to the deceleration that a known braking system would produce.
Certain assumptions about the car had to be made before the necessary calculations could be performed. It was
assumed that the car would weigh 230kg, and the location of the car’s CG was approximated based on the
positions of the engine and driver. A deceleration of 1.5g was assumed, since the car would not likely be
decelerating at a rate faster than this. Using this information, the amount of the car’s weight on both the front and
rear set of tires under deceleration could be determined. From this information the normal forces and frictional

Copyright to IJIRSET DOI:10.15680/IJIRSET.2020.0903034 212

 ISSN(Online): 2319-8753
ISSN (Print): 2347-6710

International Journal of Innovative Research in Science,

Engineering and Technology
(A High Impact Factor, Monthly, Peer Reviewed Journal)
Visit: www.ijirset.com
Vol. 9, Issue 3, March 2020

forces experienced by the tires can be determined to produce given deceleration rate.
With the help of friction forces the next step is to be determined braking torque. Brake torque is the simply
amount of torque required to produce given deceleration.
Torque brake = R tire × F friction
With the braket or ques required at the front and rear tires and compare it with the brake torque developed by the
caliper. By comparing the torques the caliper selection are finalized. By keeping all above information into
account the below parameters are finalized.
- Disc diameter – 55 mm PCD of the Disc – 100 mm
- Size of bolts- M6 (8.8 grade with metal lock nuts)
- Thickness of the disc- 4mm
- Calipers-Vespa double pistoncaliper(withborediameter30 mm)

III. BRAKING SYSTEM SPECIFICATIONS

Table -1: Braking System Parameters

Sr.No. Parameters Value

1 Driver Force 400 N
2 Leaverage Ratio 6:1
3 Master Cylinder Diameter 19.05mm
4 Area Of Master Cylinder 285.022 mm2
5 Caliper Piston Diameter 30 mm
6 Area Of Caliper Piston 706.85 mm2
7 Tire Diameter 10 Inch
8 Disc Thickness 4mm
9 Wheel Base 1600mm
10 Mass Of Vehicle 230kg
11 Weight Of Vehicle 2256.3n
12 Height Of Cg 310mm
13 Cg From Front Axle 880mm
14 Decelearation 1.5g
15 Velocity 16.66m/s

- Front calliper: Vespa double piston callipers having bore dia. 30mm
- Rear callipers: Vespa double piston callipers having bore dia. 30mm
- Master cylinder : Maruti 800 tandem master cylinder having bore diameter 19.5 mm
- Pedal ratio : 6:1

IV. BRAKE CALCULATIONS

-
Deceleration a = 1.5×9.81 = 14.71m/s2

- C.G. height= ycg =310mm=0.31m

- Distance of C.G. from front axle = Xcg = 880mm = 0.88m

- Wheel base = b =1600mm =1.6m

- Rolling radius = r = 205 mm= 0.205m Mass of car = 230 kg

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 ISSN(Online): 2319-8753
ISSN (Print): 2347-6710

International Journal of Innovative Research in Science,

Engineering and Technology
(A High Impact Factor, Monthly, Peer Reviewed Journal)
Visit: www.ijirset.com
Vol. 9, Issue 3, March 2020

- Normal Forces On Front And Rear Tyres-

Nrear =585.45 N

Nfront =1670.85 N

% Of Normal Force On Front Tyre=74.05%

- Braking Torque Required, µ = 1.5

- Frictional Forces On Front Tires Ff = 2506.275 N

- Frictional Forces On Rear Tires Fr = 878.175 N

- Braking Torque On Front Tires

- Trf = 513.786 N-M (Required)

- Braking Torque On Rear Tires

-
Trr = 180.025 N-M (Required) Pressure = 8.42 N/mm2

Stopping distance:

Stopping distance is the distance measured between break applied by the driver and the vehicle gets complete stop. The
distance travelled by the vehicle when brake is applied. The stopping distance depends upon several factors including
deceleration rate, percentage of grade for operation, vehicle speed, road surface characteristics.

Stopping distance, d = 8 m

Brake Torque Developed-

Td = 1104.096 N-M (Developed)

By comparing torque required for braking and the torque developed by caliper, we preferred the Vespa calipers for
our vehicle.

V. BRAKE DISC

The brake disc is used to stop the car/motorcycle with the help of calliper pads. The calliper pads are actuated by a
fluid present in the hydraulic circuit. The wheel assembly of the car consists of knuckle (upright), stub, hubs, bearings
and disc. The brake discs are mounted on the hub which is connected to the wheels directly. The disc is mounted
behind the hub. The knuckle have a special arrangement for mounting a calliper on it. The part of the disc is inserted in
the space present between the calliper pads. The part of the disc which is in contact with the calliper pads is known as
pad area on the disc.

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International Journal of Innovative Research in Science,

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Vol. 9, Issue 3, March 2020

Fig -1: Brake Disc

5.1 Thermal Analysis Of Brake Disc:

For analysing the discs some assumptions are to be done as well as calculations of some parameters are required.
Considering mass of the car is 230 kg. Now considering the car is travelling at a speed of 65 km/hr on a race track
( formula race track) and it suddenly applies a brake which decelerates the car and at the end car stops. During the
steady state thermal analysis the disc get analysed for maximum temperature distribution on the pad area of the disc in
order to understood proper heat dissipation takes place through the disc surface.
Initial temperature (ambient temperature) = 22° C
- Velocity = 65 km/h =17.67 m/s
- Mass (M) = 230 kg
- Weight = 2256 N
- Coefficient of friction between road and tyre (µ) = 0.8
- Brake disc diameter = D = 0.155 m
- Axle weight distribution (ᵞ) = 0.4
- Percentage of kinetic energy that disc can absorb =(f)= 0.9
- Acceleration due to gravity (g) =9.81 m/s2
- Coefficient of friction between disc and pads = (µ) = 0.3
- Kinetic energy of the system can be given as,
K.E. = 6463.8 J Deceleration Time (t),
v= u + at t= 2.85 sec
- Braking power (pb) = K.E. / t pb = 2268 W
- Heat flux = (Q) =Pb/A
= 120195 W/m2

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 ISSN(Online): 2319-8753
ISSN (Print): 2347-6710

International Journal of Innovative Research in Science,

Engineering and Technology
(A High Impact Factor, Monthly, Peer Reviewed Journal)
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Vol. 9, Issue 3, March 2020

But the distribution of braking torque vehicle is about 64:40 and the heat flux for single disc can be evaluated by
dividing total heat flux by two. And by considering the weight distribution factor, the heat flux Q is equals to 23040
W/m2.

5.2 Analysis of Brake Disc

We used ANSYS for the analysis and validation of the design.

(a) (b)
Fig -2: (a)Steady state thermal analysis of Temperature distribution through disc, (b). Steady state thermal analysis of
total heat flux through disc.

5.3 Brake Pedal

The pedal design is important, especially at the contact point from the foot of the driver, because that is where the
most force would be applied. In general, the brake pedal needed to take a 2000 N force, but needed to also be
lightweight for design points. Also, the height of the pedal pad should be about the average height of the length of a
male’s foot from heel to sole, about 270 to 290 mm , but be able to accommodate smaller and larger sized feet. The
Brake Pedal is manufactured in aluminium by considering factor of safety 1.2.

The brake pedal is designed according to design procedure of bell crank lever. The master cylinder pivot is about
35mm above the brake pedal pivot. For designing the brake pedal the pedal ratio is considered as 6:1 and the driver
force considered as 400 N.

Fig -3: Brake Pedal Initial and Final Design Sketch.

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ISSN (Print): 2347-6710

International Journal of Innovative Research in Science,

Engineering and Technology
(A High Impact Factor, Monthly, Peer Reviewed Journal)
Visit: www.ijirset.com
Vol. 9, Issue 3, March 2020

5.4 Analysis of Brake Pedal

(a) (b)
Fig. 4:(a) Static Structural Analysis of Total Deformation Of Brake Pedal, (b) Static Structural Analysis Of
Equivalent (Von-Mises) Stress.

To eliminate small objects, connected component labelling is applied to the resultant image.(c) represents text detection
by applying second set of criteria which eliminates all the objects whose area is less than 300 and filled area is less than
500.

Fig -5: Brake disc & caliper assembly

VI. CONCLUSIONS

It was necessary to design a braking system which is light in weight and compact while still provides adequate stopping
power and to cover these aspects we selected hydraulic braking system. While doing this project we understood how an
effective braking system should be designed, manufactured and optimized. This Project has cleared our basic
knowledge about mechanical system design. This idea has given us hands on experience on designing a hydraulic
braking system which is very useful for future.

Copyright to IJIRSET DOI:10.15680/IJIRSET.2020.0903034 217

 ISSN(Online): 2319-8753
ISSN (Print): 2347-6710

International Journal of Innovative Research in Science,

Engineering and Technology
(A High Impact Factor, Monthly, Peer Reviewed Journal)
Visit: www.ijirset.com
Vol. 9, Issue 3, March 2020

REFERENCES

[1] Pruthviraj Vitthal Wable, “Design and Analysis of Brake Disc”, UG Student, Department of Mechanical Engineering, Trinity college of
Engineering and Research, Pune, Maharashtra India.
[2] William Kinkead, ME et al. “Design and Optimization of a Formula SAE Vehicle”
[3] Amogh Deshpande, “International Journal of Research in Science and Technology”, (IJRST) 2015, Vol. No. 5, Issue No. III, Jul-Sep.
[4] David E. Keyser, “Hydraulic brake systems and components for off-highway vehicles and equipment”, MICO, Inc. 1911 Lee Boulevard.
[5] Swapnil R. Abhang, D.P.Bhaskar “International Journal of Engineering Trends and Technology (IJETT) – Volume 8 Number 4- Feb 2014”
[6] Megan Scheitlin “Renewable Energy Vehicle Project: Pedal Box Design for Formula SAE”
[7] V.B.Bhandari “Machine Design-Published by Tata McGraw Hill Education Private Limited”
[8] Milliken, William F., and Douglas L. Milliken. Race Car Vehicle Dynamics. Warrendale, PA, U.S.A.: SAE International, 1995. Print.
[9] Hammond, A., Flay, R. (2014). Aerodynamic Design of a Formula SAE Race Car. The University of Aukland
[10] Dahlberg, H. (2014). Aerodynamic Development of Formula Student Race Car, KTH Royal Institute of Technology.
[11] Richard Gross, “Chapter 9: Design of braking system”, FSAE Racing vehicle Dynamics.

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