Brake Disc / Rotor

S. No. Material Design Advantage & Application

1 Cast Iron Single piece Design Non Performance Cars

Drag racing (Higher Heat

2 Steel Single thin piece of steel capacity & Light weight)

Layered Layered Steel Sheets and Race Cars; Dishing &

3 Steel laminated together warping are eliminated

Heat Dissipation is very

4 Aluminium good; Motorcycles uses this

Rotors made from high amount

of carbon mixed with iron so as
High Carbon todissipation
heat capacity and thermal High performance vehicles
5 rate also silicon
added to this so that noise and
vibrations can be reduced
 High end sports cars and
race cars; light weight; high
Composite
6 heat and thermal
Ceramic dissipation; retains 85% of
heat
 Restriction Cause of Failure
Solution Image

Use 2 piece cast iron

Brakes should not be Cracking of inner design with aluminium
abused a lot surfaces joint

Not Durable

Reduced Capacity
to absorb heat;
Can't be used for
prolonged braking
solutions due to
low melting point
 Given Data

S. No. Parameters Symbols

1 Acceleration due to gravity (g) g
2 Gross Weight of the vehicle (w) w
Weight of Front Axle without the application of Brakes (Static Ff
3 State)
Weight of Rear Axle without the application of Brakes (Static Fr
4 State)
5 Height of Centre of Gravity CG (h) h
6 Wheel Base (l) l
7 Coefficient of friction b/w road and tires u

8 Piston Diameter (Calliper) Pcd

9 Master Cylinder Diameter Md

10 Brake Disc/ Rotor Diameter Rd
11 Tire Radius r
12 Deceleration rate d
13 Pedal ratio P.R.
14 Mass m
15 (/4)
16 Pressure of Calliper Pc

Calculation

S. No. Parameters Symbols

1 Total Weight Transfer WT
2 Dynamic Weight on Rear Wr
3 Dynamic Weight on Front Wf
4 Braking Force on Rear Wheels Fb
5 Braking Torque Required Tb
6 Brake Line Pressure / Pressure of Master Cylinder Pm
7 Clamping Force Fc
8 Available Torque Ta
9 Stopping Distance S.D.
10 Braking Efficiency
 Value
9.81 m/s2

Sub Calculations

S. No. Parameters
Brake Line Pressure /
1 Pressure of Master Cylinder
2 Clamping Force

0.8*g m/s2

0.785

Formula Values
w*u*h/l #DIV/0!
Fr - WT #DIV/0!
w - Wr #DIV/0!
u*Wr #DIV/0!
Fb*r #DIV/0!
Symbols Formula Value

Pm F/A P.R.*m*g/ (/4)*Md #VALUE!

Fc
 Thermal Analysis

Given Data

S. No. Parameters Symbol Values

1 Mass of Disc m
2 Specific Heat Capacity Cp
3 Time taken for stopping the vehicle T
4 Developed Temperature difference t
5 Outside Radius of Disc R
6 Inside Radius of Disc r
7 3.147
8 Thermal Conductivity Tc

Calculations

S. No. Parameters Symbol Formula

1 Heat Generated Q m*Cp*t
2 Area of Disc A *(R2 - r2)
3 Heat Flux Hf Q*A/T
4 Thermal Gradient Hf / T c

Modal Analysis
 Formula Values
R 2
R*R 0
r2 r*r 0

Value
0
0
#DIV/0!
#DIV/0!