This document discusses different types of braking systems, focusing on ceramic disc brakes. It describes the manufacturing process for ceramic disc brakes and their advantages over conventional disc brakes, such as being 50% lighter, able to withstand higher temperatures, and resistant to wear and corrosion. Ceramic disc brakes are currently used in high-performance cars and some commercial vehicles due to their improved braking capability but higher initial cost compared to conventional disc brakes. The document concludes ceramic disc brakes will likely be more widely adopted in the future automotive industry.

1. ANEESH K.K
S8 PRODUCTION
ROLL NO: 503

2. CONTENTS
Braking system
Types of braking system
Disc brakes
Ceramic disc brakes
Ceramic disc brakes and conventional disc brakes
Manufacturing of ceramic disc brakes
PCCB
Advantages & Disadvantages of ceramic brake disc
Applications

3. MAIN REQUIREMENTS
Brakes must be strong enough to stop the vehicle
within the possible distance in an emergency. (safety)
Brakes should have good anti-fade characteristics also
on constant prolonged application its effectiveness
should not decrease.

4. STOPPING DISTANCE OF A VEHICAL DEPENDS
Vehicle speed
Condition of road surface.
Condition of tyre thread.
Coefficient of friction b/w tyre thread & road surface.
Coefficient of friction b/w brake disc/drum & brake
pad.
Braking force applied by the driver.

5. TYPES OF BRAKES
According to the purpose
 Service or primary brakes
 Parking or secondary brakes
According to the construction
 Drum brakes
 Disc brakes
According to the method of actuation
 Mechanical brakes
 Hydraulic brakes and Air brakes
 Electric brakes
 Vacuum brakes
According to the extra braking effort
Servo brakes or power assisted brakes
Power operated brake

6. DISC BRAKE

7. TYPES OF BRAKE MATERIALS
Grey cast iron disc
 Heavy
 Rust formation
Aluminium disc
 Light
 Less resistant to heat and fade
Carbon-fiber disc
 Heat resistant
 Needs high working temperature
Ceramic disc
 Inorganic and non-metallic
 Hard and brittle material
 High heat and abrasive resistance
 Can sustain large compressive load

9. CERAMIC DISC BRAKES AND CONVENTIONAL
DISC BRAKES
Grey cast iron disc is heavy which reduces acceleration,
uses more fuel.
Ceramic disc brake weighs less than conventional disc
brakes but have same frictional values, used in F-1 racing
cars etc.
CDB good at wet conditions but conventional disc fails in
wet conditions.
CDBs are 61% lighter, reduces 20kg of car, apart we can
save the fuel, resulting in better mileage. Improve the
shock absorber. We can add more safety features instead
of the current weight.

10. MANUFACTURE OF CERAMIC DISC BRAKE
In earlier days disc brakes were made from
conventional brittle ceramic material.
DIAMLER CHRYSLER made carbon fibre
reinforce brake disc to avoid the brittle property.
Short carbon fibres + carbon powder + resin
mix(at 1000 c sintering) = stable carbon frame
work.
After cooling ground like wood brake disc obtains
its shape.
Add silicon to the required shape and insert in the
furnace for the second time.
Resins : thermo plastics resins and thermo setting
resins .

11. COATING OF CERAMIC ON CONVENTIONAL
BRAKE DISCS
FRENO Ltd. used metal matrix composite for disc, an
alloy of aluminum for lightness and silicon carbides
for strength. The ceramic additive made the disc
highly abrasive and gave a low unstable coefficient of
friction.
SULZER METCO Ltd. special ceramic coating,
developed thermal spray technology as well as
manufacturing plasma surface.

12. PORSCHE CERAMIC COMPOSITE DISC BRAKES
(PCCB)
This is manufactured
using a high vacuum
process.
 The process involves
heating carbon
powder, resins and
carbon fibres in a
furnace at 1700 c

13. PROPERTIES OF PCCB
CDB with the involute cooling ducts for an
efficient cooling.
Offers braking response, fading stability, weight &
service life.
PCCB ensures maximum deceleration from
without any particular pressure on the brake
pedal.
Superior response under wet condition.
 New braking linings cannot absorb water.
 Cross drilled brake discs help to optimize response of the
brakes also in wet weather.

14. ADVANTAGES
50% lighter than metal disc brakes, reduces 20kg of car.
Apart from saving fuel also reduce unsprung masses with a
further improvement of shock absorber response &
behavior.
High frictional values in deceleration process Porsche- 100
to 0 km in 3 sec.
Brake temperature.
Resistance up to 2000 c .
Still runs after 300000 km need not change CDB.
No wear, maintenance free and heat and rust resistant even
under high oxygen concentration.
Heavy commercial can be braked safely over long distance
without maintenance.

15. DISADVANTAGE
High initial cost and high cost of production.

16. APPLICATIONS
FORMULA-1 cars and sports cars
Porsche 911 turbo- with a top speed of 305 km/h and
acceleration from rest to 100 km/h in 4.2s. Its engine
3.6 L with 420 hp max torque 560 Nm is still running
with PCCB.
911GT2 and Mercedes Benz’s futuristic vision GST is
going to reinforce CDB .

17. APPLICATION IN PORSCHE 911

18. CDB IN UPPER CLASS LIMOUSINES

19. CDB IN SPORTS CARS

20. CONCLUSION
CDB due to its advantages over the conventional
brake discs are going to be the brake disc for cars in
the future. With the success of Porsche turbo car,
many other racing cars and commercial vehicles are
going to implement CDB in cars.

21. REFERENCES
AUTOMOTIVE MECHANICS – CROUSE/ANGLIN
www.porsche.com
www.diamlerchrysler.com
www.mercedesbenz.com
www.howstuffworks.com

23. QUESTIONS