Brake report

Pranjal saini
Chintan varde
Ankit pandey

Design condition of our Go kart

Wheel base (L) 1.207m
Center of gravity height (H) 0.258m
Distance of CG from center of rear wheel (b) 0.45m
Total weight (W) 160kg

Condition for locking of brake : Amount of braking force generated should be greater than
amount of longitudinal force that a tire can sustain which can be calculated from the tire data
and the slip ratio should be -1.
We have chosen TVS Apache RTR 160 double piston floating caliper since it has two piston
and floating caliper applies friction force from both side of the brake disk which is more
effective.

Brake system specification

Brake type Single disk brake at rear axle

Brake fluid Dot 3
Brake disk OD 200mm
Brake disk ID 80mm
Master cylinder diameter 19.15mm
Area of master cylinder 288mm2
Dia of piston 28mm
Area of piston 615mm2
Coefficient of friction between tire and road 0.65
Coefficient of friction between pad and 0.4
caliper
Front to rear distribution 40:60
Pedal ratio 4:1

Calculation
 Mean effective radius

By considering uniform wear theory

R= r1+r2/2
= 0.04+0.1/2 = 0.07m

 Deceleration

a = µg(L-b)/L+µh
= 0.65 * 9.8(1.027-0.45)/1.027+(0.65*0.258) = 3.462m/sec2

 Load transfer = Wah/Lg

 =(160*3.462*0.258)/1.027
= 139.15N

 Static load at front axle = 1596.6*0.4 = 627.84 N

 Static load at rear axle = 1596.6*0.6 = 941.76

 Dynamic analysis

At time of braking , load on front tire increases as compared to rear tire .

Shifting CG to backwards increases load transfer thereby increase in α of rear tire , which is
condition for overstear
Above one is better condition for braking , with this in rear drive vehicle you can accelerate
more with better traction.

 Normal force for front wheel

FNF = static load at front – load transfer
= 627.84 – 139.15 = 488.65 N

 Normal force on rear wheel

FNR = static load at rear wheel + load transfer
= 941.76 + 139.15 = 1080.91 N

 Force exerted by caliper on disk

FCP ={ (FNR / µ) * Rdisk }/Rmean
= {1080.91 *0.1 *0.65}/0.07
 = 1002.94 N

 Force offered by caliper on piston

Fcaliper = Fcp /µ2
= 1002.94/0.4
= 2507.35 N

 Pressure on piston
Pr = Fcaliper/2* area of piston
= 2507.35/2*0.000615
= 2.03*106 N/m2

 Brake torque
T = FNR*µ*Rdisk
= 1080.91*0.65*0.1
=70.20 N

 Force on master cylinder

Fmc = PR* Amc
= 2.03*106 *0.000288
=584.64 N

 Force on pedal = force on master cylinder / mechanical leverage

= 584.64 / 4
= 146.16 N

Thermal analysis

 KE = heat loss + friction loss + work done

 Heat loss = force exerted by caliper disk * velocity * time

Velocity = (Vwheel * Rmean) / Rwheel
= (16.67*0.07) / 0.139
= 8.94m/sec

 Heat loss = 1002.94*8.94*T (i)

= 8966.28 T Joule

 Work done = force *displacement

= m*a*s
= 160*3.462(ut – 1/2at2)
= 553.92( 16.67 T – 1.731T2) (ii)

 KE = 1/2mv2 = ½ *160*16.672
=22231.11 Joules (iii)

 Friction loss = force *µ*Vwheel*time

= 160*9.81*0.65*16.67*T
 = 17007.4 T (iv)

By substituting value of eqn (i),(ii)and (iv) in eqn (iiii) we get, the value of T

T= 0.6426 sec

 Stopping distance
S = (u+v) / 2*T
S = (16.67 + 0)/2 *0.64
= 5.35 m

In actual condition there is a time lap between application of brake and fully development of
brake , additional stopping distance Sa = Td *v , where Td = response time of brake
V = initial velocity

 Total rubbing area of disc = rubbing area of disc *2

= π/4 ( D2 – d2) *2
= π/2 (2002 – 802)
= 29946.90 mm2

 Brake time = v= u+at

= 0= 16.67 – 3.462 t
t = 4.81 sec

 Brake power = KE * weight distribution / brake time

= (22231.11 *0.6)/ 4.81
= 2773.11 watt (as weight distribution at rear is 60% )

 Heat flux
Q = brake power / total rubbing area of disk
= 2773.11 / 0.029
= 92746.15 Watt / m2
Models of disk
Analysis
Pedal analysis