New Horizon Institute of Technology and Management, Thane

Program: Mechanical
Academic Year: 2021-22
Class: BE Semester: VII
Course Name: Project Code: MEP701
Presented By: 1. Parikshit Pandey
2. Narendra Pogul
3. Shreekar Rahate
4.Pankaj sahu
Group Id:ME182213

Department: Mechanical Engineering

www.nhitm.ac.in New Horizon Institute of Technology and Management,
Thane

New Horizon Institute of Technology and Management, Thane

Stage 1: Presentation

Title of Project
(Brake system design, optimization and manufacturing a
with student SAE international safety rules.)

www.nhitm.ac.in
New Horizon Institute of Technology and Management, Thane
 Abstract
The braking system is the most important system in a car. If the brakes fail, the result may
be disastrous. An FSAE race car brake system is different from the conventional brakes.
Thus The methodology followed while designing such a braking system is different. We as
a part of an FSAE team have taken up this project to develop a Hydraulic Braking system
of an FSAE car.The design of an effective braking system plays a major role in high
performance formula cars since the stopping distance and speed control during cornering
are the important part of any race. Everyone wants their car to go fast, but the braking
system should be capable to stop immediately and safely. Any car with highly effective
braking system fills confidence in the driver. It also increases driving pleasure.
Keywords :- caliper,master cylinder, rotor.
1. Introduction
The braking system was designed as a hydraulic system for a one-man
performance racing vehicle.The three main categories/ components designed
and analysed for this system are the first component, the overall functionality
and free variables of the braking system will be analysed for optimum caliper,
master cylinder and brake disc size selection. The second main component of the
design encompasses the pedal assembly design. This design includes the gas
pedal, brake pedal and master cylinder orientation as well as the throttle senor
and emergency stop placement and orientation. The third and final main
component involves the design of the brake disc . The constraints and limitations
based on the competition rules of these components will be defined later in each
of their sections. The objective of these major component designs waste
minimizes the weight for the lightest design possible while at the same time
designing to all of the mechanical and thermal conditions that the system would
be subjected to. In the pedal assembly and brake disc design sections the
optimization processes will be discussed as well as the finite element analysis
that supports the final design. In the final sections of the report the
manufacturing of the pedal assembly and brake disc will be discussed.
Problem Statement
● As the braking of an automobile vehicle is a very crucial safety part so the
responses from the brake pedal to the final braking must be very quick which
was a failure of a mechanical type braking system and is very well achieved by
the hydraulic braking system which provides quick braking.
● The brake force generated by hydraulic braking system is very high as
compared to the mechanical braking which is a very important factor for
today’s super and hyper series of vehicles.
Scope of the Project
The project involves research on Hydraulic Braking system employing disc brakes.
Floating disc system has been studied and implemented. An adjustable pedal box
design which takes into consideration driver comfort by studying driver
ergonomic data has been implemented. It provides three adjustments so that the
driver can select the best suited adjustment .The system takes into account
safety measures such as providing two independent brake circuits for the front
and rear wheels so that in case one fails, the other is still working. It also involves
installation of a brake over travel switch that gets actuated when the brake fails
and stops the car.
2. Literature Review
•[1] Vivek Singh Negi , Nayan Deshmukh , Amit Deshpande (2017):-The objective of
this design was to produce light weight brake assembly, reliable throughout
different terrains and Effective to satisfy the wheel-lock condition. initial testing of
the setup and its implementation on the vehicle, the overall adjustability of the
braking system Meets the design goals of possessing better and responsive braking
system. The other design objective of achieving Minimum stopping distance was also
achieved.
•[2] Mohd Usama , Gagan singhal (2018) :- This work contains the design and
analysis of braking system for FSAE/SAE SUPRA .designing and analysis of various
Components of braking system. Along with it, different Engineering Software like
SOLIDWORK and ANSYS are Utilized for the analysis of brake disc, considering
structural And thermal aspects. The basic aim of this Work is to achieve the
required standards for brake design in SAE SUPRA and to scale through the
dynamic test at the Competition. All the components of braking system such as
master Cylinder, brake disc, brake lines etc. Are examined under Extreme
condition.
•[3] Rohit Kawade, Gaurav Pardeshi, Sagar Jadhav, Amar Jadhav (2020) :-
designed and manufactured lightweight braking system to implement in SAE Supra
vehicle. Also tested to satisfy its design requirement in critical condition. To achieve
maximum potential of system the driver requires 40kg pedal force, which is very
less than that of the panic braking force that can be applied by average driver. Each
and every components of brake system such as brake disc, caliper, master cylinder
etc. are tested under extreme condition. Various factors affecting the net heat
generation and dissipation from the disc brake is determined by the generation of
heat by using velocity of car.
3. Methodology
The need for the braking system is to increase the safety and
Manoeuvrability of the vehicle. Design procedure of braking System consists
following steps –
 Calculating maximum braking capacity of vehicle means Maximum
possible deceleration of vehicle based on tyre Model.
 Calculate desired braking ratio between front and rear Wheels for locking
of all the four wheels at the same time.
 Selection of brake disc considering structural and Thermal stresses.
Gantt Chart
References
•[1] Vivek Singh Negi , Nayan Deshmukh , Amit Deshpande, “Design of Braking
System of BAJA Vehicle”,International Journal of advance engineering and research
development,Volume:04, Issue: 11 November 2017, eISSN:. 2348-4470
•[2]Mohd Usama , Gagan Singhal ,“Design and Analysis of Braking System for
FSAE”, International Journal for Scientific Research & Development,
Volume:06, Issue: 02 2018, ISSN (online): 2321-0613
•[3] Rohit Kawade, Gaurav Pardeshi, Sagar Jadhav, Amar Jadhav ,“Design and
Analysis of Brake System of a Single Seat Race Car”, International Journal of
Research in Engineering and Technology, Volume:07, Issue: 03 March 2020,
EISSN: 2395-0056