Brake Calculation

Figure 1: Brake Operation

Driver Foot F P Q

FMC

Master PMC Caliper Cylinder Piston

Fpiston Brake Pad

FBP

Brake Disc Q Air

FD

Wheel

FB

Ground

= Force = Pressure = Heat

Diagram 1: Brake System Layout

Weight Distribution: To calculate the braking force needed, the weight distribution must first be determined. The total weight of the car has been estimated at 400kg. The center of Gravity (CG) was also gained to facilitate further calculations, the CG is determined at: x: 1465.7 y: 200 z: 298.91 Weight distribution is determined like so: z x

Requirements: The general deceleration needed to be induced by the braking system, can be determined from the given set of rules by the Perodua organizing committee: B.8 Brakes The vehicle must demonstrate the ability to stop within 20 m from 50 km/hr to 0 km/hr in straight line. 0km/h 50km/h

20m The decelerations need to induce a stopping from a velocity of 50km/h in a 20m stretch: u v s = 50 km/h = 0 m/s = 20 m = 13.89 m/s

V2 = u2 + 2a.s 0 = 13.892 + 2 (a) (20) a = -4.823 m/s2 a = 0.45 g The subsequent total braking force (FBT) of the car obtained from this deceleration is: FBT = m.a FBT = 400(4.823) FBT = 1929.2 N A higher deceleration rate is targeted to ensure maximum efficiency: a = 0.8 g a = 0.8(9.81) a = 7.848 m/s2

Theoretical Braking Force: The theoretical braking force is determined to estimate the total braking capability of the cars front and rear tires. This will be based upon the weight distribution of the car.

z MF FBF 1235.7mm 34.96% 664.3mm 65.04% MR FBR x

Wb= 1900mm
Figure 1: Braking Force Distributed Load

FBF= MF a FBF= 166.64 (7.848) FBF= 1097.543N

FBR = MR a FBR= 233.36 (7.848) FBR = 2041.657N

Pedal Force: Typically on a street car effort is at or below 18 kg. In high performance vehicles and race cars we try to keep the leg force required below 54 kg. Thirty six kilograms is ideal for most race applications. Experience has shown that a pedal ratio of 6.2:1 is recommended (with 5.5:1 being the recommended minimum) to replace most of the brake force assist that was provided originally by the vacuum assist and the original equipment pedal ratio of 3.5 to 4.0:1. The force from the drivers foot is subsequently increased via the pedal ratio into the force for the master cylinder. To calculate the force actuated on the Master Cylinder, assume driver force is at 43kg: (Fd)

6.2 : 1

(FMC)

Figure 4: Pedal Ratio

FMC = Fd . RP FMC = 43 (9.81) ( ) FMC = 1687.32 N

This force is then converted into brake line pressure through the actuation of the cylinder bores.

( (

) )

PMC = PP

FD Front Brakes ( )

Fpiston = 6051868(6.61 x 10-4) Fpiston = 3997.897N

FBP FBP

Fpiston

Ppiston

Fpiston = FBP FD = FBP . 2BP FD = 3997.897(2 x 0.42) FD = 3358.234N

= 3358.234(0.0895) = 300.5619Nm r FBF = 1100N re

Rear Brakes ( )

FD

Fpiston = 6051868(2.019 x 10-3) Fpiston = 12219.45N

FBP FBP

Fpiston

Ppiston

Fpiston = FBP Fd = FBP . 2BP Fd = 12219.45(2 x 0.42) Fd = 10264.34N

= 10264.34(0.0965) = 913.5259 Nm re r

FBR = 3346N

Parking Brake:

W sin 18 W cos W

18

The vehicle must be equipped with a parking brake capable of holding the vehicle (including driver) on an incline of 18.

FB = W sin = 400(9.81) sin 18 = 1212.6N

b Nr a

Nf 18

Mr = - W sin (c) W cos (b) + Nf (Wb) 0 = - 3924 sin 18 (423.91) 3924 cos 18 (664.3) + Nf (1900) Nf = 1575.34N Ff = Nf = 0.8(1575.34) = 1260.27N > 1212.6N

Finite Element Analysis (FEA): Brake Pedal:

From the Von Mises and Displacement analyses, we can conclude that the force applied to the brake pedal is well within the limitations of the pedals strength properties and design properties.

Pedal (Acceleration & Clutch)

From the Von Mises and Displacement analyses, we can conclude that the force applied to the pedal is well within the limitations of the pedals strength properties and design properties.

Tyre
Diameter, d Track, T (F) Track, T (R) Wheel Base, wb Coeffecient of Friction, : : : : : 546mm 1200mm 1220mm 1900mm 0.8 x: 1338.45mm y: 200mm z: 298.91mm

Remarks
Obtained Obtained Obtained Obtained Targeted Obtained

Chassis
Center of Gravity, COG

Engine
Speed (max), v Pedal Ratio , PR Driver Forces Disc (rotor) Diameter, d Master Cylinder diameter, DMC Area Cylinder diameter, AMC Brake Pad Coeffeicient, BP Piston Diameter , DP Piston Area , AP Effective Radius Mass, M Front Mass ,MF Rear Mass, MR : km/h 6.2 : 1 33kg 210mm 18.84 mm : : : : 0.000279m2 0.4 Viva Mira 50.7mm 29.0mm 6.61 x 2.019 x 10-3m2 10-4m2 0.089mm 0.0895 400kg 139.85kg 260.15kg Calculated Obtained Calculated Calculated Obtained Obtained

Brake
: : :

Calculated Obtained

Car
: : : Calculated Calculated

Nomenclature
M m mf mr r re d v u a aL s t h wb A A piston A MC BP Fd FBT FBF FBR Fpiston FBP FFP FRP FD RP Mo Ppiston PMC total mass mass front mass rear mass radius effective radius diameter velocity initial velocity acceleration lateral acceleration distance time center of gravity height wheel base area piston area master cylinder area friction of coefficient brake pad friction of coefficient Pedal force total braking forces braking forces of front Braking forces of rear piston forces brake pad forces front piston forces rear piston forces disc force pedal ratio moment piston pressure Master Cylinder pressure