Design and Analysis of a Disc Rotor for a Small Race Car's Braking System

The purpose of these report is to record the information regarding on Final Year Project.
It includes the data gathering, calculations and design stage that had been gone through
by author. The objective of the project is to design the disc rotor for a braking system of
Formula SAE according to rules and regulation of Formula SAE car.
FSAE car braking system that is designed by author is based on the dual hydraulic circuit,
which the standard front to rear split that generally used in rear wheel driven car.
Moreover, the braking system uses a disc braking system instead of using drum brakes.
Advantages of using disc brakes system are more fade resistant, possible to stop in wet
condition, reduce the overall weight of the car and easy to make service during the race.
In the Literature Review, the first stage in designing is made it according by the rules and
regulation of Formula SAE guidelines. Moreover, the formulas were identified in getting
the right formula of braking performance, component sizing, and adhesion utilizations of
the car.
In the Result and Discussion, it shown the target of brake bias setting is 55:45 (front to
rear) has been calculated in the Excel form. Also, adhesion utilization curve is generated
and shown the both axles will lock up simultaneously at deceleration rate, z=k at 0.58g.
Next, the rotor have been designed by using CATIA. Also, the rotor's thermal analysis
have been analyzed using ANSYS Workbench. The manufacturing process of the rotor
have also been proposed by the author. As conclusion, a certain amount of understanding of
the brake system has been obtained.