Engineering Report:

Braking Systems
Will Groves

Table of Contents

Abstract

ABS: Materials

ABS: Effect and Implications

Disk Brakes: Materials

Disk Brakes: Effect and Implications

References

Abstract

This report aims to justify why certain materials are used for two different braking systems.
These two braking systems are Anti-Lock Braking Systems (ABS) and Disk Braking
Systems. Throughout this report, the cultural, social and environmental effect and
implications of these braking systems and their manufacture will be discussed.

Anti-Lock Braking Systems (ABS)

Overview
Anti-lock brakes reduce the risk of tyres skidding by applying the brakes periodically so that
the tyres will not lock and skid. This results in more effective braking and also allows drivers
to continue steering around obstacles during emergency braking.2 4
Materials
The main components in the anti-lock braking system are: a wheel speed sensor unit,
electronic control unit, hydraulic control unit and a master cylinder assembly.1 4
The wheel speed sensor is constructed of low carbon steel as magnetism if required for the
unit to function correctly and a high proportion of iron results in better magnetism. The
electronic control unit is printed upon a circuit board which is protected then placed within an
aluminium housing as there is more heat generated in the unit than regular electric circuits so
plastic is not suitable as aluminium dissipates heat more effectively. The hydraulic control
unit is made of approx. 40% steel housing, 20% copper wire elements and 40% hydraulic oil.
The master cylinder is constructed of steel and aluminium for strength, wear resistance and
heat dissipation. All the electrical wiring inside the brakes is copper as copper has good
conductivity, is cheap and has high ductility.2
Effect and Implications
The use of ABS brakes in cars nowadays has been a highly effective addition to the safety of
a car. ABS brakes allow people to travel at higher speeds for longer as the ABS system will
prevent the tyres from locking and skidding so a much more effective and safer stopping
procedure is achieved. Also, ABS brakes are useful as they do not require much adaptation to
be placed on top of disk brakes. The ABS system also maintains improved braking in weather
conditions where some other braking systems may not provide the most effective braking e.g.
slippery roads. Lastly, ABS brakes have resulted in less crashes and skidding on the road and
so, allow people to drive knowing that in the case of an emergency stop, they will have a
much lower chance of skidding and crashing.3
However, despite the many positives of ABS braking systems, the manufacturing of these
braking systems can cause environmental concerns if the factories producing these systems
do not operate under ethically correct practices. A more important fault in the brakes is that
the brake linings since 1902 have been constructed of asbestos fibres. These fibres, when
inhaled cause lung cancer so as this was discovered, car manufacturers ceased to construct
brake linings out of asbestos.3

Disk Brakes
Overview
The disk brake is the most common type of brake in modern cars. The disk (or rotor) is
connected to the axle and a caliper containing two brake pads is attached to the rotor.
Hydraulic pistons operate the brake pads, pushing them against the rotor, causing friction and
slowing the vehicle.3
Materials
Commonly, the disk rotor is constructed of grey cast
iron as it is suitable for this application. This being
because it can be easily machined, has good
compressive strength and heat dissipation, and has
good vibration dampening.5 6 In high performance
racing cars, rotors are often constructed of carbon fibre
or a composite material as it is much lighter however
more expensive and less wear resistant.7
The brake linings in modern cars are generally
constructed of a metal fibre composite; usually steel
fibres, copper fibres and brass chips however carbon, wool and other materials can be added.
These materials are then bonded together using a phenol formaldehyde resin. This choice of
materials is selected for its good heat dissipation and a stable coefficient of friction.9
The remainder of the braking unit is usually constructed of steel as it is strong, cheap and
easily machined into the complex shapes required.7

Effect and Implications

The use of disk brakes in modern automobiles has improved many peoples lives due to the
increased levels of vehicle safety achieved by installing this braking system. Again, similar to
ABS, disk brakes provide more effective and safer braking at higher speeds than other
braking systems e.g. drum brakes. This allows drivers to feel more comfortable at higher
speeds, e.g. freeway, where in the case of an emergency stop; the vehicle will stop more
efficiently than those equipped with drum brakes. Furthermore, disk brakes have better heat
dissipation than drum brakes so over large downhills, continual braking will be safer and
brake fade (loss of braking ability due to high heat caused by friction) will not be as severe.
Disk brakes are also able to be modified quite easily to have ABS brakes installed on-top-of
to further improve the braking efficiency and safety. This braking system also maintains
improved braking in weather conditions where some other braking systems may not provide
the most effective braking e.g. slippery roads. Lastly, disk brakes help reduce crashes on the
road which is an important feature of braking systems.3
However, similar again to ABS, the brake linings since 1902 were been constructed of
asbestos fibres. These fibres, when inhaled cause lung cancer so as this was discovered, car
manufacturers ceased to construct brake linings out of asbestos.3

References

http://www.cdxetextbook.com/brakes/brake/abs/title.html May 2009 Accessed 6.7.15

http://www.madehow.com/Volume-2/Antilock-Brake-System.html 2015 Accessed 6.7.15

Engineering Studies The Definitive Guide vol. 1 ed. 2 2012 Copeland, Paul
Accessed 6.7.15

pg 89-94

http://brainonboard.ca/safety_features/active_safety_features_abs.php 2008 Accessed

6.7.15
5

http://www.sae.org/events/bce/tutorial-ihm.pdf 2010? Accessed 6.7.15

Engineering Studies The Definitive Guide vol. 1 ed. 2 2012 Copeland, Paul
Accessed 6.7.15
7

http://en.wikipedia.org/wiki/Disc_brake May 2015 Accessed 6.7.15

http://www.cdxetextbook.com/brakes/brake/disc/title.html May 2009

Accessed 6.7.15

Engineering Studies The Definitive Guide vol. 1 ed. 2 2012 Copeland, Paul
Accessed 6.7.15

pg 116

pg 119