DESIGN, ANALYSIS AND OPTIMIZATION STUDY OF THE

BRAKING SYSTEM. APPLICATION TO FORMULA STUDENT

RACING CAR

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 Executive Summary

Designing the braking system of Formula 1 student racing cars is the key area of concern for this
project. Therefore, analyzing the designed braking system of Formula 1 student racing cars and
structuring a “6 piston mono-block caliper” braking system.

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 Table of Contents
1. Description of your artefact.........................................................................................................4

1.1 Context of the project.............................................................................................................4

1.2 Aim and objective of the project............................................................................................4

1.3 List of feature that will include..............................................................................................4

1.4 Identify added value that the project provides.......................................................................4

1.5 Identify the intellectual challenges involved.........................................................................5

2. Methodology................................................................................................................................5

2.1 Describe approach..................................................................................................................5

2.2 Justify approach.....................................................................................................................5

3. How does your project relate to your degree course and build upon the units/knowledge you
have studied/acquired......................................................................................................................5

3.1 Highlight Aspects...................................................................................................................5

References........................................................................................................................................6

Journals........................................................................................................................................6

Websites.......................................................................................................................................6

Article...........................................................................................................................................6

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1. Description of the artefact

1.1 Context of the project

Designing the braking system of Formula 1 student racing cars. Analyzing the designed braking
system of Formula 1 student racing cars and structuring a “6 piston mono-block caliper” braking
system
Master cylinders of two distinct levels are being operated by a brake pedal, with an aftermarket
brake pedal, and may flow by the braking system of a racing car. One of the two cylinders
operates the rear stopper, another manages the rear stoppers (Muralidharan et al. 2018). Metallic
and organic brake pads are used in road cars, however, carbon or ceramic brake pads are used for
racing cars, Formula 1 cars include calipers of aluminum six-pot.

1.2 Aim and objective of the project

The main aim of this project is to structure a “6 piston mono-block caliper” braking system for
Formula 1 student racing cars.

The objectives of the project include:

● To design the braking system of Formula 1 student racing cars

● To analyze the designed braking system of Formula 1 student racing cars
● To do optimization study of the braking system of Formula 1 student racing cars

1.3 List of feature that will include

The features of the braking system may include calipers of 6 piston mono-block that ensures
comparatively better disc performance along with maximum braking force and stiffness. The
stiffness ratio or lightness can be counted as one of the significant features of this braking system
(Brembo.com, 2017). The higher friction coefficient is provided by the carbon-ceramic discs
compared to cast iron that made calipers of 6 piston mono-block.

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1.4 Identify added value that the project provides

The calipers of 6 piston mono-block can add a structured approach that secures a durable,
reliable, and comfortable efficiency level (Seo et al. 2017). The different kinds of features such
as the friction coefficient level and the stiffness ratio can add value to the braking system.

1.5 Identify the intellectual challenges involved

The challenge that is involved in using the caliper system is that it makes noise as it hits the pad,
calipers cause vibration with brake pads and make a squeaking sound (Shah et al. 2017).
However, 4 piston mono-blocks can be considered better than that of 6 piston mono-block
calipers.

2. Methodology

2.1 Describe approach

Different journals have been searched by different other writers and different websites have been
checked, and it has been concluded that “Brembo’s 6 piston monobloc caliper”. Different
interviews had been carried on with engineers of “Brembo”, and other brake manufacturing
companies, along with the racers (Brembo.com, 2017). It had been concluded that the caliper of
the 6 piston mono-block of “Brembo” is incomparable to other calipers of the braking system.

2.2 Justify approach

The study of different journals about the braking systems used in road cars and racing cars
allowed theoretical knowledge. The interview with engineers of “Brembo”, provided a clear
justification of the features of the “6 piston monobloc caliper” (Usama and Singhal, 2018). The
interview with other brake manufacturing companies provided an overall knowledge of the ways
different braking systems work and their sustainability. Therefore, all the knowledge gained from
both the qualitative and quantitative research methods, used in analyzing the fact that the “6
piston mono-block caliper” is useful for Formula 1 racing cars.

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3. How does this project relate to the degree course and build upon the units/knowledge of
studied/acquired

3.1 Highlight Aspects

Knowledge has been gained about the different braking systems used in racing cars and road cars
and the calipers and brake pads such as calipers of aluminum six-pot (Ugemuge and Das, 2020).
However, “6 piston mono-block calipers” has been included in the braking system of Formula 1
racing cars, based on the knowledge gained from the interviews and journals.

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References

Journals
Muralidharan, V., Balakrishnan, A., Vardhan, V.K., Meena, N. and Kumar, Y.S., 2018. Design
of mechanically actuated aerodynamic braking system on a formula student race car. Journal of
The Institution of Engineers (India): Series C, 99(2), pp.247-253.
Seo, B., Park, S., Park, J. and Jeong, C., 2017. Development of a Monoblock Brake Caliper with
Resin Pistons for Premium Automobiles.
Shah, R., Shah, C. and Thigale, S., 2017. Design and analysis of a hydraulic brake caliper.
Volume, 8, pp.33-41. ]
Ugemuge, M. and Das, S., 2020. Topology Optimisation of Brake Caliper (No. 2020-01-1620).
SAE Technical Paper.

Websites
Brembo.com, (2017). FROM 100 KM/H TO 0 IN JUST 2.2 SECONDS: FIND OUT HOW IT'S
POSSIBLE WITH BREMBO BRAKES. Available from
https://www.brembo.com/en/company/news/5-factors-that-make-a-brembo-braking-system-
unbeatable. Accessed on 29.10.2021.

Article
Usama, M., and Singhal, G., (2018). Design and Analysis of Braking System for FSAE. Available
from https://www.researchgate.net/publication/340442949_aking_System_for_FSAE.
Accessed on 30.10.2021. DOI:10.13140/RG.2.2.26149.65760.