2. INTRODUCTION:
The main motive of undertaking this project of “Braking system of Go-
Kart” is to study and evaluate the performance under severe braking
conditions and there by assist in disc rotor design and analysis. This
study is of disc brake used for Go-kart. SOLIDWORKS package is a
dedicated modeling package used for design the disc brake rotor.
3. BRAKE REQUIREMENTS:
The brakes must be strong enough to stop the vehicle with in a
minimum Distance in an emergency.
The driver must have proper control over the vehicle during braking
and the vehicle must not skid.
The brakes must have good anti-fade characteristics i.e. their
effectiveness should not decrease with constant prolonged application.
The brakes should have good anti wear properties.
4. DISC BRAKE:
A disc brake consists of a cast iron disc bolted to the wheel hub and a
stationary housing called caliper.
The caliper is connected to some stationary part of the vehicle and It
containing a piston.
In between each piston and the disc, there is a friction pad held in position
by retaining pins, spring plates etc.
The passages are drilled in the caliper for the fluid to enter or leave each
housing.
These passages are also connected to another one for bleeding.
Each cylinder contains rubber-sealing ring between the cylinder and piston.
5. PRINCIPLE:
A disk brake works on the principle of Pascal’s Law/Principle of
transmission of fluid pressure.
Pascal’s law which states that “pressure at a point in a fluid is
equal in all directions in space”. According to this law when
pressure is applied on a fluid it travels equally in all directions
so that uniform braking action is applied on wheels.
The principle used is the applied force (pressure) acts on the
brake pads, which comes into contact with the moving disc. At
this point of time due to friction the relative motion is
constrained.
6. WORKING:
When the brakes are applied,
hydraulically actuated pistons move the friction pads in to
contact with the disc, applying equal and opposite forces on
the later. On releasing the brakes the rubber-sealing ring
acts as return spring and retracts the pistons and the friction
pads away from the disc. The main components of the disc
brake systems are below:
The Brake pads
The caliper, which contains the piston
The Rotor, which is mounted to the hub
7. BRAKE FUNDAMENTALS:
As we decide to apply brake on rear two wheels of our go-
kart and the fundamentals of the brake are below:
STOPPING DISTANCE:
The distance a vehicle will
travel from the point when its brakes are fully applied to when
it comes to a complete stop.
BRAKEBALANCE:
The ratio of braking force
distributed between the front and rear wheels.
BRAKE FADE:
Brake fade is a term used to
describe the partial or total loss of braking power used in a
vehicle brake system.
8. BRAKING TORQUE:
The brake torque is the moment of braking
force about the center of rotation.
BRAKE EFFICIENCY:
The brake efficiency is defined as the braking
force produced as a percentage of the total weight of vehicle.
CLAMPING FORCE:
The force pressing each brake pad against the
disc is called as clamping force.
9. MATERIAL SELECTION:
As we decide the aluminium as material for disc rotor design,
because of following factor
Less weight
Corrosion resistance
PROPERTIES VALUES
ULTIMATE TENSILE
STRENGTH
310 Mpa
TENSILE YIELD
STRENGTH
276 Mpa
DENSITY 2700 Kg/m3
MODULUS OF
ELASTICITY
68.9 Gpa
POISSON RATIO 0.33
