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INTRODUCTION
• Braking system is an energy converting system that converts
vehicle movement into heat while on application of clamping
force using friction pads on brake rotor. This is done by applying
PREPARED BY, pressure on back side of piston pushing the brake pads against
BRAKES KSHTRAPATI MAHTO the rotor disc causing frictional force at contact and inhibiting
the motion of the vehicle
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WORKING OF BRAKES
TYPES OF BRAKES
 MECHANICAL BRAKES o A COMMON MISCONCEPTION ABOUT BRAKES IS THAT BRAKES SQUEEZE
• DRUM BRAKES AGAINST A DRUM OR DISC, AND THE PRESSURE OF THE SQUEEZING ACTION
• DISC BRAKES SLOWS THE VEHICLE DOWN. THIS IS IN FACT A PART OF THE REASON FOR
SLOWING DOWN A VEHICLE.
 HYDRAULIC BRAKES
o ACTUALLY BRAKES USE FRICTION OF BRAKE SHOES AND DRUMS TO CONVERT
 POWER BRAKES
KINETIC ENERGY DEVELOPED BY THE VEHICLE INTO HEAT ENERGY.
• AIR BRAKES
o WHEN WE APPLY BRAKES,THE PADS OR SHOES THAT PRESS AGAINST THE BRAKE
• AIR HYDRAULIC BRAKES
DRUMS OR ROTOR CONVERT KINETIC ENERGY INTO THERMAL ENERGY VIA
• VACCUM BRAKES FRICTION.
• ELECTRIC BRAKES

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Components of Disk Brake Steps

The main components of a disc brake are:
• The brake pads.
• The caliper, which contains a piston.
• The rotor, which is mounted to the hub.

Materials for Brake Pads Justification

They're typically made of iron, copper, steel and
graphite all mixed and together and bonded to
form the pad material.
The reason that these pads are so common is
simple -- metallic brake pads are cost-effective
and durable.

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BORE DIAMETER CALCULATIONS

Pads Compressibility
When the driver applies brakes, the pedal force gets converted into hydraulic
pressure in the master cylinder. This pressure, which acts as an actuating force,
is transferred through the brake fluid to the caliper mounted on the disc. Here
the actuating force gets converted into the clamping force. Magnitude of this
force depends upon the bore diameter and number of pistons in the caliper. The
clamping force pushes the friction pads against brake rotor thereby generating a
frictional force between them which is responsible for braking torque. The
generated braking torque must be greater than the required braking torque to
stop the vehicle. Required braking torque on a particular wheel is calculated
from the load on the

The above equation gives us the magnitude of clamping force which is applied
on the rotor by the piston. The diameter and number of pistons can be decided
by performing iterations based on the above equationand depending uponspace
availability

Clamping force
Materials for Caliper
The brake caliper is the assembly which houses the
brake pads and pistons. The pistons are usually made of
plastic, Aluminium or chrome-plated steel.
Calipers are of two types, floating or fixed. A fixed
caliper does not move relative to the disc and is thus
less tolerant of disc imperfections.

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Justification
Phenol formaldehyde resin is frequently used as a binding
agent. Graphite can serve as a friction material as well as
binding agent. Another friction material commonly used is
zirconium silicate.An Italian producer conducts research to
use cement as a cheap and less energy-intensive binding
agent.The table below outlines the make up of a common
brake pad.
Disadvantages
1. Disc brake assemblies are costlier than drum brakes
2. The pads wear off fast compared to brake shoe lining of drum.
3. Complete protection to the disc from road residue is provided with great
difficulty.
4. The high temperature operation of disc brake causes evaporation of the
brake fluid and weakening of seal.
5. Disc brake offer difficulty in installing hand brakes.
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Advantages
1. Disk brake requires less effort (brake torque) to stop the vehicle compare to
drum brake.
2. It generates less heat compare to drum brake for the same brake torque.
3. Ease of maintenance as disk brake is outside the wheel rim.
4. It cools down faster compare to drum brake.
5. If worn out brake shoes are not changed at proper time it can cut the brake
drum in drum brake. Disk brake does not have such problem.
6. It is less likely to skid compare to drum brake in wet condition.
7. It is much safer than drum brake in hard braking condition. Under such
condition drum brake can lock up the rear wheel.
8. It has brake pad wear indicator which is not there in drum brake.
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