Design and Analysis of Hydraulic Brake Caliper

Prajwal Gawali, Prof. S. R. Kulkarni

Abstract: An important factor in handling of any vehicle is making it to come quick and easy stop. Retarding a vehicle in manner such that driver has complete control over it is essential. The safety while braking is paramount and is quantified by evaluating mathematical model of braking. The evaluation of model is done by calculation of braking torque and comparing it with required value. The paper discusses ideas for using various components in the system, design variables and logic behind selecting correct values of those variables. The design of braking system consists of evaluating multitude of scenarios and using them to achieve optimum, yet effective braking. The data related to them is used to extract average values of design parameters, making the theoretical calculations as realistic as possible. Baja SAE is an intercollegiate design competition run by the Society of Automotive Engineers (SAE). Teams of students from universities all over the world design and build small off-road cars. The goal in Baja SAE racing is to design, build and race off-road vehicles that can withstand the harshest elements of rough terrain. The vehicles used in Baja SAE racing are often similar in appearance to dune buggies. The Main objective of the event is to design and build a vehicle which is safe, easily transported, easily maintained and fun to drive. Each Teams goal is to a build an ATV with least weight without compromising to the build quality of the vehicle. Using OEM components in vehicle leads to increase the overall weight of the vehicle, so the Design and Development of each component owing to required specifications becomes a necessary part while designing the vehicle. OEM Brake Caliper increases the weight of the vehicle with its technical specifications not conforming to the required necessity of the BAJA vehicle. The OEM caliper are designed according to the requirement of the vehicle and the Motorsport Company producing it. The Endurance limit and factor of safety of the OEM caliper are considered according to the use of caliper and the fatigue life of the vehicle. Design of Customized Brake caliper for BAJA vehicle is therefore necessity of the team to reduce the weight of the vehicle. This will enable us to decrease the unsprung mass of the vehicle along with decrease in Scrub radius of the vehicle. The Design specifications of the customized Brake alliper are specified according to the use of the vehicle, fatigue life and conforming to the mathematical calculations required to stop the vehicle. Mathematical Calculations were done for the braking force, clamping force, stopping distance of the vehicle owing to the requirement of the BAJA vehicle keeping in mind the dynamic events held at the competition. According to the calculations and the required specifications, Design of Customized Brake caliper were done for BAJA vehicle 2019. The Design specifications of the caliper are specified in the report below along with the design of the caliper and Design Analysis of the caliper.

Keywords: BAJA, SAE, OEM Brake Caliper, Unsprung mass, Braking Systems, Scrub Radius, Analysis, Frictional Braking, Biasing effect, Weight Transfer, Hydraulic Pressure, Pascal?s Law