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BRAKE DISC ROTOR DESIGN:

Rotors are made of gray cast iron for following reasons It is relatively hard and resists wear.
It is cheaper than steel or aluminum.
It absorbs and dissipates heat well to cool the brakes.
The disc brake mainly consists of the brake disc, cylinder, brake caliper, tubing, hydraulic
power source and other components. In braking, the high-pressure hydraulic oil into the hole
by the pressure, push the piston moves to the right, while promoting the rack to the left, both
sides stepped up the brake disc to achieve braking.
The main technical parameters are the rated braking torque, braking radius, disc diameter,
disc thickness, the radius of the brake linings, brake clearance, the work chamber push rod
stroke, the piston rod axial displacement, chamber push rod stroke, friction plate opening
force, the brake lining thickness, the total area of the two brake pads, brake efficiency and
brake efficiency performance factor and so on. Given the basic parameters of a light vehicle
shown in Table.
Parameter name

Parameter value

Vehicle mass m

1140 kg

Body length, width, height

3.495, 1.475, 1.460 (m)

Rim diameter

0.3048 (m)

Wheelbase L

2.360 (m)

Table 1: Basic parameters of a four wheel vehicle (Alto Lxi)

The brake diameter:


The brake diameter D should be possible to get bigger, then be increased effective radius of
the brake can reduce the brake caliper clamping force, lining the block to reduce the unit
pressure and temperature. Limited by the diameter of the rim, brake disc diameter is usually
chosen as the rim diameter of 70 ~79%.
Therefore we have,
Diameter of rim of wheel

= 0.3048 m

But, Diameter of rotor disc is 70 to 79 % of the diameter of rim.


Therefore, Diameter of rotor disc = 0.70 diameter of the rim
= 0.70 0.3048
= 0.21336 m
= 213.33 mm
In alto car diameter of disc is 215 mm.

The thickness of the brake disc:


The brake disc thickness has impact on the quality and the temperature rise when the brake
disc working. To make the quality more smaller, should not take the thickness of the brake
disc larger; and in order to reduce the temperature, the thickness of the brake disc should not
be taken too small. The brake disc can be made solid, or air in the middle of the disc, a
ventilation channel is casted for the need of cooling. Generally, the desirable solid brake disc
thickness is range of 10~20mm, the thickness of ventilated brake discs is more 20~30mm. So,
the brake disc thickness B is taken as 10mm solid discs.
Taking, Disc thickness t = 10 mm
Kinetic energy K.E = 0.5 M V

2
= 0.5 1140 38.05

= 825247.42 J
Where K.E = kinetic energy (J)
M = mass of vehicle (kg)
V = velocity of vehicle ( m/s

Heat generated when applying braking action on disc brake = K.E


Hg = K.E
Hg = 825247.42 J
md mass of the disc (kg)
CSpecific heat (

J
. k)
kg

t temperature difference ( )
tf

final temperature ( )

t i initial temperature ( )
Hg=md C t
825247.42=2.8 460 t

t=640.72
So,
t=( t f t i)
640.72=( t f 22 )
t f =662.72
Here,

heat generated per wheel =

825247.42
4
206311.85 J

Area of rubbing faces

2 314 ( 107.52 66.52 ) 106


0.044 m 2

heat flux

= heat generated/ time/ twice the projected area=206311.85 /5.4/ ( 2 0.044 )


434157.93 W /m2