International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 06 | Jun 2025
p-ISSN: 2395-0072
www.irjet.net
DEVELOPING AND MANUFACTURING OF CUSTOM BRAKE CALIPER Sujal Jadhav1, shivanand Jadhao2, Rushikesh Ingole3, Soham Kachare4, Mr.P.S Aglawe5 Department of Mechanical Engineering All India Shri Shivaji Memorial Society’s College of Engineering, Pune ---------------------------------------------------------------------***--------------------------------------------------------------------Abstract - The Brakes are the fundamental and crucial system in the automotive industry, playing a pivotal role in ensuring vehicle safety, control moving vehicle, and dynamic performance of the vehicle. A well-functioning braking system allows drivers to control their vehicles and respond to unexpected situations promptly.
Design and Analysis of Hydraulic Brake caliper [2]: Prajwal Gawali, Prof. S. R. Kulkarni. Determination of Braking force is most crucial aspect to be considered while designing any braking system. The generated braking force should be always be greater than the required braking force. Space and assembly constraints are also an important factor while designing the caliper body. The seal groove geometry is pivotal to the operation of the caliper as it allows the piston to retract after the required clamping force has been applied.
Disc brakes are more efficient brakes than other brakes for racing vehicles. Disc brakes offer unparalleled stopping power, allowing for rapid and effective deceleration. The design of disc brakes facilitates efficient heat dissipation during intense braking conditions. It has an open design that allows for easy visual inspection and maintenance. Disc brakes offer precise control and responsiveness for racing drivers.
Design and Testing of Custom Brake Caliper of a Formula Student Race Car [4]: Mosam Ugemuge, Sreethal Das. The paper gives a detailed study on designing and testing a brake caliper which is light weight thus enhancing the agility and reducing the unsprang mass. In OEM caliper the least thickness of disc which can be used was 4mm. The bench testing of caliper shows that caliper can work fine in range of 6.894 Mpa.
Disc brakes has mainly two components disc and caliper. The flat surface of disc acts as the friction points for brake pads. When the brake pedal is pressed, the pads contact the disc, converting the wheel's rotation into thermal energy through friction. Calliper works as clamp for holding the disc when brake pedal is pressed that slows down the vehicle. The design of the calliper can be optimized by keeping factors like bleeding port, pads mount, fluid flow path in consideration.
Rotor Diameter
180mm
Weight of the Vehicle
225 kg
1. INTRODUCTION
Tire Diameter
584.2m
49:51
m (23”)
Weight Distribution
625.24
Trackwidth
1270m m
Table -1: Design Parameter
A brake is a device by means of which artificial frictional resistance is applied to moving vehicle, in order to stop motion of vehicle (SAE International, 2003). A brake caliper usually made up of Cast Iron or Ceramic and which is assembled in wheel or axle. To stop the wheel, friction material is in the form of brake pads (mounted in device called a Brake caliper) is forced mechanically, Hydraulically or Pneumatically against both sides of the disc. Friction causes the disc and attached to slow or stop.
Torque on Shaft
N mm Length of Shaft
mm Coefficient of Friction
1.1 Literature Survey
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Impact Factor value: 8.315
0.85
Master Cylinder 20.64m m Piston Diameter 5:1
Pedal Ratio
STATIC LOAD CALCULATIONS: Front Axle W1 = (W × C) / L = (225 × 9.81 × 584.2) /1422.4 W1 = 906.48 N Rear Axle W2 = (W × C) / L = (225 × 9.81 × 696.54) / 1422.4 W2 = 1080.87 N Where, W = load in N = Weight × g. C = Longitudinal distance of Centre of Gravity from rear axle in mm. L = Wheel base in mm
Belhocine Ali and Bouchetara Mostafa (2013) [1]: analyzed the thermomechanical behavior of the dry contact between the brake disc and pads during the braking phase. The thermal-structural analyze is then used to determine the deformation and the Von Mises stress established in the disc, the contact pressure distribution in pads.
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