CERAMIC DISC BRAKES
HANEESH JAMES
S8 ME8
ROLL NO: 20
INDRODUCTION


Today’s 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.
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.
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.
TYPES OF BRAKES
Purpose Construction Method of Extra
actuation braking
effort
Service
brakes
Parking
brakes
Drum brakes
Disc brakes
Mechanical
brakes
Hydraulic
brakes
Electric
brakes
Servo brakes
Power
operated
brake
DISC BRAKE- CONSTRUCTION
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.

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.
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(at1000ْ 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, 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 .
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.


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 .
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.


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
1700ْ c is a high vacuum process
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.
Daewoo’s Nexia- 100 to 0 km in 4 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 concn.
Heavy commercial can be braked safely over
long distance without maintenance.
APPLICATIONS



FORMULA1- in mid 90’s 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 Benz’s futuristic
vision GST is going to reinforce CDB .
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.
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.
REFERENCES





AUTOMOTIVE MECHANICS –
CROUSE/ANGLIN
www.porsche.com
www.diamlerchrysler.com
www.mercedesbenz.com
www.howstuffworks.com
QUESTIONS