PRODUCT DESIGN LAB

DESIGN AND DEVELOPMENT OF DISC

BRAKES

MOHAMMED AATHIL_130021601114
MOHAMMED CASSIM IHJAS_130021601109
MOHAMMED ANWAR_1300216011117

INTRODUCTION
According to Cambridge dictionary, brakes refers to a device that
makes a vehicle go slower or stop, by a pedal, bar, or handle that
makes this device work.
In other words, brake is a device for slowing or stopping a vehicle or
other moving mechanism by absorption or transfer of energy of
momentum, usually by means of friction.
TYPES OF BRAKES:
Some of the commonly used brakes are
Drum brakes
Disc brakes

DISC BRAKES
Disc brakes are a brake system that
slows a wheels rotation by
squeezing an attached metal disc in a
viselike hydraulic caliper.
Disc brakes use the same principle as
bicycle handbrakes, but on a bike the
brake pads press against the wheel
itself.
PARTS OF DISC BRAKE:
Brake disc
Brake calliper
Brake pads

PRINCIPLE OF WORKING
1. Leverage
2. Hydraulics
3. Friction

TYPES OF DISC BRAKES

1.FIXED CALLIPER TYPE:
The fixed calliper type uses one or two
pistons mounted on each side of the rotor
(in each side of calliper). The calliper is
mounted rigidly and does not move.
2.FLOATING CALLIPER TYPE:
In floating calliper type the pad on the
inside of the rotor is moved into contact
with the rotor by hydraulic force. The
calliper which is not held in fixed position
moves slightly bringing the outside pad in
contact with the rotor. It makes use of
guide pins and bushings.

ADVANTAGES
Disk brake requires less effort (brake torque) to stop the vehicle
compare to drum brake.
Ease of maintenance.
It cools down faster compare to drum brake since most of the friction
area of a rotor is exposed to air
It is less likely to skid compare to drum brake in wet condition since
rotors scrape off water more efficiently.

DISADVANTAGES
It is expensive compare to drum brake.
If any air remains in disk brake system, it can cause accident as the
brake will not work effectively.
Disk brake assembly has more moving parts and much complex than
drum brake.

1.DISMANTLING OF PARTS
Tools used:
Screw driver
Allen key
Ratchet
Steps followed:
1. First remove the guide pin cover nut using screw driver.
2. Then remove the guide pin using allen key.
3. Mounting plate is removed using ratchet or box spanner.
4. Guide pin holds the brake pad with the calliper when the guide
pin is taken out we can easily remove the brake pads.
5. Now we can able to see the pistons inside the calliper.

2.IDENTIFICATION OF PARTS

CALIPER ASSEMBLY

DISC BRAKE SETUP

ROTOR OR DISC

CALIPER

BRAKE PAD

GUIDE PIN

3.BILL OF MATERIALS
S.NO

PARTS

MATERIALS

MANUFACUTING
PROCESS

Nos.

DISC

CAST IRON or
REINFORCED CARBON

MOULDING,
DRILLING AND
HARDENING

CALLIPER

ALUMINIUM

MILLING

HUB

ALLOY STEELS

MILLING

BRAKE PAD

METALLIC OR SEMI
METALLIC COMPOSITES

POWDER
METALLURGY

PISTON

CHROME PLATED STEEL

MACHINING

GUIDE PIN

STEEL

MACHINING

BLEED NUT

ALLOY STEEL AND

STAINLESS STEEL

MACHINING

4.PRODUCT STRUCTURE
Disc brake
Disc hub
assembly

Disc
Hub

Calliper
assembly

Piston
Brake pad
Guide pin
Bleed nut

Fluid hose

FUNCTION STRUCTURE

To enclose the
bleeder valve

To restrict
motion

To create
friction

To rotate along
with the wheels

To guide the
pads

To hold the pin

STUDY OF FUNCTIONS
S.NO

PARTS

FUNTIONS

DISC

STOP THE WHEEL

CALLIPER

HOUSING FOR PISTON

HUB

HOLDS THE DISC

BRAKE PAD

PROVIDES FRICTION

PISTON

TRANSMITS PRESSURE

FLUID HOSE

WAY FOR FLUID FLOW

BLEED NUT

BLEEDING THE CALLIPER

5.FREE HAND SKETCHING

CALLIPER

DISC

BRAKE PAD

BLEED NUT

CALLIPER PIN


6.BRAKE CALCULATION
Data considered:
Mass of the vehicle=147kg
Mass of passengers=2*70=140kg
Static weight distribution=50:50(vehicle mass only)
Passenger weight distribution=30:70
Total mass of vehicle, =287kg
Calculation:
i. Value of deceleration, :
Apache takes 3.9sec to reach a speed of 60kmph

ii. Braking force, :

iii.
Static weight distribution in front, :

iv. Static weight distribution in front, :

v. Dynamic load transfer, :

Where,
= maximum possible deceleration achievable by the vehicle
= distance from the ground to the CG point
WB = the vehicle wheelbase (distance from the front axle to the rear axle)
= Total weight of vehicle

vi. Dynamic load at the front, :

vii. Dynamic load at the rear, :

The co-efficient of frictional force between the tyres and the road is 0.75(for asphalt)
allows transmission of force from tyres to ground. This load is being dynamic load on the
axle.
viii. Frictional force on front, :

ix. Frictional force on rear, :

Similarly,

Diameter
of the wheels = 17 inches

Radius of the wheels,
x. Torque on front wheels, :

xi Torque on rear wheels, :

We know that,
Where,
Effective radius of the disc,


xii. Clamping force on front wheels, :

xiii. . Clamping force on rear wheels, :

We know that,

Pedal
ratio = 4:1
Optimum load applied by a human = 150 N

xiv.
diameter of master cylinder = 1.5 inches = 38.1 mm

xv. Pressure in the mc,

THEORETICAL STOPPING DISTANCE AND

TIME
140

120

100

80
velocity
acceleration
stopping distance
60

stopping time

40

20

0
0

20

40

60

80

100

120

140

PART INTERFACE ANALYSIS

Part 1= calliper
Part 2= brake pad
Part 3= rotor
Part 4= guide pin
Part 5= bleed nut
P1
P1
P2
P3
P4
P5

P2

P3

P4

P5

No. of interfaces = 5

7.FEATURES TABLE
PART N0. PART NAME
P1
CALLIPER

P2

BRAKE PAD

P3
P4

ROTOR
GUIDE PIN

P5

BLEED NUT

FEATURE ID
P1F1
P1F2
P1F3
P2F1
P2F2
P2F3
P3F1
P4F1
P4F2
P5F1

FEATURE
FLAT
CURVED
CURVED
FLAT
FLAT
FLAT
FLAT
CURVED
CURVED
CURVED

8.ASSEMBLY GRAPH

F1

PART 1

F1

F2

PART 2

F1

F2

PART 3

F3

F3

F1

F2

PART 4

F1

PART 5

9.3D CAD MODEL

10. 2D DRAWING
CALLIPER

BRAKE PAD

BLEED NUT

BRAKE DISC

GUIDE PIN

CONCLUSION
Thus the brake system for the apache two wheeler has been designed,
modelled and drafted for manufacturing. The brake calliper is designed
based on calculations and already available callipers.

REFERENCE
Fundamentals of vehicle dynamics by Gillespie
http://www.sae.org/search?searchfield=brake%20system
http://en.wikipedia.org/wiki/Disc_brake
http://car.about.com/ad/thingsyouneedtoknow/ig/Disc-brakes
http://www.kobelt.com/pdf/brochure_brake.pdf