ceramic disc brakes 1

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CONTENTS Braking system

Types of braking system

Disc brakes Ceramic disc brakes

Ceramic disc brakes and conventional disc brakes

Manufacturing of ceramic disc brakes

PCCB

Advantages & Disadvantages of ceramic brake disc

Applications


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MAIN REQUIREMENTS

Brakes must be strong enough to stop the vehiclewithin the possible distance in an emergency. (safety)

Brakes should have good anti-fade characteristics also

on constant prolonged application its effectivenessshould not decrease.


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STOPPING DISTANCE OF A VEHICAL DEPENDSVehicle speed

Condition of road surface.

Condition of tyre thread. Coefficient of friction b/w tyre thread & road surface.

Coefficient of friction b/w brake disc/drum & brakepad.

Braking force applied by the driver.


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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


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DISC BRAKE


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TYPES OF BRAKE MATERIALS Grey 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


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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 discbrakes but have same frictional values, used in F-1 racingcars 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 shockabsorber. We can add more safety features instead of thecurrent weight.


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MANUFACTURE OF CERAMIC DISC BRAKE

In earlier days disc brakes were made fromconventional brittle ceramic material.

DIAMLER CHRYSLER made carbon fibre reinforcebrake disc to avoid the brittle property.

Short carbon fibres + carbon powder + resin mix(at1000 c sintering) = stable carbon frame work.

After cooling ground like wood brake disc obtainsits shape.

Add silicon to the required shape and insert in thefurnace for the second time.

Resins : thermo plastics resins and thermo settingresins .


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COATING OF CERAMIC ON CONVENTIONAL

BRAKE DISCS FRENO Ltd. used metal matrix composite for disc, an

alloy of aluminum for lightness and silicon carbides forstrength. The ceramic additive made the disc highlyabrasive and gave a low unstable coefficient of friction.

SULZER METCO Ltd. special ceramic coating,

developed thermal spray technology as well asmanufacturing plasma surface.


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PORSCHE CERAMIC COMPOSITE DISC BRAKES

(PCCB)

This is manufacturedusing a high vacuumprocess.

The process involves

heating carbonpowder, resins andcarbon fibres in afurnace at 1700 c


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PROPERTIES OF PCCB

CDB with the involute cooling ducts for anefficient cooling.

Offers braking response, fading stability, weight &service life.

PCCB ensures maximum deceleration fromwithout 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 thebrakes also in wet weather.


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ADVANTAGES 50% 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- 100to 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 evenunder high oxygen concentration.

Heavy commercial can be braked safely over long distancewithout maintenance.


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DISADVANTAGE

High initial cost and high cost of production.


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APPLICATIONS FORMULA-1cars and sports cars Porsche 911 turbo- with a top speed of 305 km/h and

acceleration from rest to 100 km/h in 4.2s. Its engine3.6 L with 420 hp max torque 560 Nm is still runningwith PCCB.

911GT2 and Mercedes Benzs futuristic vision GST isgoing to reinforce CDB .


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APPLICATION IN PORSCHE 911


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CDB IN UPPER CLASS LIMOUSINES


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CDB IN SPORTS CARS


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CONCLUSION CDB due to its advantages over the conventional brake

discs are going to be the brake disc for cars in thefuture. With the success of Porsche turbo car, manyother racing cars and commercial vehicles are going toimplement CDB in cars.


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REFERENCES

AUTOMOTIVE MECHANICS

CROUSE/ANGLIN

www.porsche.com

www.diamlerchrysler.com

www.mercedesbenz.com

www.howstuffworks.com
http://www.porsche.com/http://www.diamlerchrysler.com/http://www.mercedesbenz.com/http://www.howstuffworks.com/http://www.howstuffworks.com/http://www.mercedesbenz.com/http://www.diamlerchrysler.com/http://www.porsche.com/


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QUESTIONS

ceramic disc brakes 1

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