BRAKE DESIGN
The objective of this Brake design was DRUM BRAKE DESIGN
to design brakes for BAJA vehicle so that it
could withstand the off-road condition. The
brake design was done considering the factors
needed for design and the factors affecting the
performance of brakes. The brakes are
designed meticulously by our team satisfying
both the design and manufacturing goals.
The brakes were designed mainly to
withstand the worst case which it will be
experiencing while off-road test conditions.
The team uses learned engineering practices
to design and for manufacture.
The design of brakes were done
according to the rule book requirements using
two Disc brakes at the front and two Drum
brakes at the rear.
BRAKE SYSTEM PARAMETERS
 Empty and loaded vehicle weight
 Static weight distribution lightly and
fully loaded
 Wheelbase
 Center of gravity height lightly and fully
laden
 Intended vehicle function
 Tire and rim size
 Maximum speed

Braking standards
Friction brakes used in automotive
applications may be of radial or drum brakes
and axial or disc brakes.
Drum brakes sub divide into external and
internal band shoe brakes and they are
designed to withstand for the maximum force
of which the rear wheel will be experiencing
along its path that is the rolling resistance
and the amount of the actuating force that
must be given to the wheel cylinders in order
to withstand that force. The maximum braking
force for rear wheels occurred when the
vehicle was stopped while moving at top
speed on normal terrain. The following were
some of the assumptions and measurements
for the drum brake parts for the Baja vehicle.
DATA
Weight of the car, W = 3430 N
(350 kg, maximum assumed weight)
Internal radius of the brake drum, r
= 90mm
Face width of the shoe, b = 30mm
Distance from the center of drum to
the shoe pivot, a= 80mm
Moment arm actuating force,
c = 145mm
Central angle of heel and toe
Θ1, Θ2, = 26°, 141°
Coefficient of friction between brake
lining and drum, µ= 0.3
Wheel radius r = 305mm
CALCULATED DATA
Force on rear wheels while braking
(maximum force condition) = 1075 N
Reaction a∞t the rear wheel due to the
loads = 1790 N
Reaction at the front wheels due to
loads = 1640 N
The design of drum brakes for the rear
took the worst condition of force that will be
acting which was found to be 1075 N and the
actuating force and braking torque for the Where,
drum brakes are tabulated. Rf -- load on front axle
Actuating force, P = 6.1 KN Rr -- load on rear axle
Braking torque, Mt =17.11 Nm w – Total weight
X -- distance of CG from front wheel
b – Wheel base
h – Height of CG from the ground

BRAKING FORCE:
DISC BRAKE DESIGN PROPORTION OF BRAKING FORCE:
The disc brakes which are also called KBF/KBR = (B+ H (μ + FR))/ (A – H (μ + FR)) = 60/40
as self adjusting brakes were chosen for Baja 60% of total braking force at the front
vehicle for using in the front wheels. They are
40% of total braking force at the rear
axial brakes which has a major advantage
than drum brakes as its ability to operate with Total braking force = 227.32kg
little fade at high temperatures. These were Fxf = 136.39kg
selected for using in the Baja vehicles in front
wheels because of the maximum force while
Fxr = 90.92 kg
braking is transmitted to the front. The
maximum forces on the front wheels occurred Components Type
when the vehicle was stopped while sloping System Independent
down the gradient. The disc brake is designed hydraulic system
according to the dimensional features Master cylinder Tandem master
assumed and measurements are given below. cylinder
Braking circuit Front/rear hydraulic
split system
Type of brake Front : disc
Rear : drum
Design parameters Results

Load on axles

Front 182.46 kg

Rear 167.18 kg
DATA
total 350 kg
Weight of the disc, W= 2 kg
Outer disc diameter, OD= 215mm
Inner disc diameter, ID = 135mm Required braking force
Effective braking radius, r = 87.5mm
Caliper area = 6300mm² Front 136.39 kg
Number of revolutions by the disc
rotor, N = 871 rpm @ 50 km/hr Rear 90.92 kg
Coefficient f friction between pad and
disc, µ = 0.4 total 227.31 kg

CALCULATED DATA Stopping distance

Force on front wheels while braking
(maximum force condition) = 1242 N
Reaction at the rear wheel due to the
loads, = 1790 N
Reaction at the front wheels due to
loads, = 1640 N
AXLE LOADING WHILE BRAKING:
Rf = w/b [x+µb]
Rr = w/b [b-x-µh]
(at a deceleration of 12.26 m
6.5m/s2)
The design of disc brakes is according
to the worst condition of the force that will be
acting which was found to be 1242 N and the
actuating force and braking torque are
tabulated.
Actuating force = 10.85 KN
Braking torque, Mt =180 Nm
 Actuating pressure required for the
pad linings = 1.72 Kpa