ANEESH K.KS8 PRODUCTION

ROLL NO: 503

CONTENTSBraking systemTypes of braking systemDisc brakes Ceramic disc brakesCeramic disc brakes and conventional disc brakesManufacturing of ceramic disc brakesPCCBAdvantages & Disadvantages of ceramic brake

discApplications

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.

STOPPING DISTANCE OF A VEHICAL DEPENDS Vehicle speedCondition 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.

TYPES OF BRAKESAccording 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

DISC BRAKE

TYPES OF BRAKE MATERIALSGrey 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

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.

MANUFACTURE OF CERAMIC DISC BRAKEIn 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 .

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.

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

PROPERTIES OF PCCBCDB 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.

ADVANTAGES50% 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.

DISADVANTAGE

High initial cost and high cost of production.

APPLICATIONSFORMULA-1 cars and sports carsPorsche 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 .

APPLICATION IN PORSCHE 911

CDB IN UPPER CLASS LIMOUSINES

CDB IN SPORTS CARS

CONCLUSIONCDB 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.

REFERENCES

AUTOMOTIVE MECHANICS – CROUSE/ANGLIN

www.porsche.comwww.diamlerchrysler.comwww.mercedesbenz.comwww.howstuffworks.com

QUESTIONS