DESIGN AND ANALYSIS OF BRAKING SYSTEM OF SAE CAR

Abstract

The following report encompasses the design of braking system. The system is one based on hydraulic braking and designed for a one-man performance racing vehicle. The objective of the system is to convert the kinetic energy of the vehicle into thermal energy, allowing the vehicle to decelerate optimally and safely. The design includes three major categories: calculation and evaluation of the hydraulic system in order to select callipers and master cylinders, the design of the pedal box, and the design of the rotors. The results and findings of the proceeding report rendered a symmetrical front and rear braking system. The Wilwood GP 200 two piston floating calliper and the Wilwood flange mount master cylinders with a ¾’ inch bore was selected for the system. An optimized pedal box was designed consisting of two pedals, (Acceleration and brake), eight mounting tabs for the two pedals and master cylinders, and two electrical sensors supports (one for the brake light sensor and the other for the emergency stop switch). The pedal box was optimized for minimal mass and satisfied the design criteria (later defined in the text). Lastly, custom rotors were designed based on the optimal material choice, analysing thermal effects and considering cost.