CERAMIC DISC BRAKES

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CERAMIC DISC BRAKES

• HANEESH JAMES
• S8 ME8
• ROLL NO 20

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INDRODUCTION

• Todays technology is in need for speed, also
  safety as well, for that deceleration is needed
  engines of max efficiency for maintaining the
  speed brakes of latest technology is used.
• Brake system are required to stop the vehicle
  within the smallest possible distance. By
  converting kinetic energy into heat energy which
  is dissipated to atmosphere.

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MAIN REQUIREMENTS

• Brakes must be strong enough to stop the vehicle
  within the possible distance in an emergency.
  (safety)
• Brakes should have good antifade characteristics
  also on constant prolonged application its
  effectiveness should not decrease.

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STOPPING DISTANCE OF A VEHICAL DEPENDS

• 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
  brake pad.
• Braking force applied by the driver.

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TYPES OF BRAKES
Purpose Construction Method of actuation Extra braking effort
Service brakes Drum brakes Mechanical brakes Servo brakes
Parking brakes Disc brakes Hydraulic brakes Power operated brake
Electric brakes
Air brakes
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DISC BRAKE- CONSTRUCTION
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COMPARISON b/w CERAMIC DISC BRAKES AND
CONVENTIONAL DISC BRAKES

• Grey cast iron disc is heavy which reduces
  acceralation, uses more fuel and has high
  gyroscopic effect.
• Ceramic disc brake weight less than carbon/carbon
  disc but have same frictional values, used in
  Formula1 racing cars etc.
• CDB good at wet conditions but carbon/ carbon
  disc fails in wet conditions.

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• Weight CDB are 61 lighter, reduces 20kg of
  car, apart we can save the fuel, resulting in
  better mileage. Improve the shock absorber and
  unsprung masses. We can add more safety features
  instead of the current weight.

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MANUFACTURE OF CERAMIC DISC BRAKE

• In earlier days disc brakes were made from
  conventional brittle ceramic material.
• DIAMLER CHRYSLER made carbon fibre reinforce
  brake disc to avoid the brittle property. First
  they used long carbon fibres the short which
  increased the efficiency.
• short carbon fibres carbon powder resin
  mix(at1000? c, sintering) stable carbon frame
  work.

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• 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, pores in the
  carbon frame work absorb the silicon melts.
  Matrix carbon reinforce the liquid silicon after
  cooling grey disc brake is ready.
• Resins thermo plastics resins and thermo
  setting resins .

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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 for strength. The ceramic additive made
  the disc highly abrasive and gave a low unstable
  coeff of friction.
• SULZER METCO Ltd- special ceramic coating,
  developed thermal spray technology as well as
  manufacturing plasma surface.

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• Ceramic phasing requires special metallic
  friction pad, deposit a layer on the brake disc.
  This coupling provides wear resistance, high and
  stable coefficient at friction.
• The coated matrix composite discs were first used
  on high performance motor cycles were reduced
  gyroscopic effect ha the additional advantage of
  making the cycles turn .

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PORSCHE CERAMIC DISC BRAKES (PCCB)

• Porsche has developed new high performance disc
  brakes, (PCCB). CDB with the involute cooling
  ducts for an efficient cooling. Offers braking
  response, fading stability, weight service
  life. Does not require substantial pedal forces
  or any technical assistance.

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• PCCB ensures maximum deceleration from without
  any particular pressure on the brake pedal. It
  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.
• The process involves of carbon powder, resins and
  carbon fibres in a furnace to about 1700? c is a
  high vacuum process

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ADVANTAGES

• 50 lighter than metal disc brakes reduces 20kg
  of car. In the case of train 36 disc brakes
  saving amount to 6 tons . 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.
• Daewoos Nexia- 100 to 0 km in 4 sec.

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• 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 concn.
• Heavy commercial can be braked safely over long
  distance without maintenance.

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APPLICATIONS

• FORMULA1- in mid 90s French sports car
  specialist Venturi.
• Porsche 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 Benzs futuristic vision GST
  is going to reinforce CDB .

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DISADVANTAGES

• High initial cost and high cost of production.
• As the advantages listed above we can hope CDB
  will work out to be cheaper in the future.

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CONCLUSION

• CDB due to its advantages over the conventional
  brake disc 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.

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REFERENCES

• AUTOMOTIVE MECHANICS CROUSE/ANGLIN
• www.porsche.com
• www.diamlerchrysler.com
• www.mercedesbenz.com
• www.howstuffworks.com

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THANK YOU
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QUESTIONS