ANEESH K.

K
S8 PRODUCTION
ROLL NO: 503

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

disc
Applications

& Disadvantages of ceramic brake

MAIN REQUIREMENTS
Brakes must be strong enough to stop the

vehicle within the

emergency. (safety)

Brakes

possible

distance

in

an

should
have
good
anti-fade
characteristics also on constant prolonged
application its effectiveness should not decrease.

STOPPING DISTANCE OF A VEHICAL

DEPENDS
Vehicle 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 &
brake pad.
Braking force applied by the driver.

TYPES OF BRAKES
According 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

DISC BRAKE

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

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
disc brakes but have same frictional values, used
in F-1 racing cars 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 shock absorber. 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.
Short carbon fibres + carbon powder + resin
mix(at 1000 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.
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 coefficient of friction.
SULZER METCO Ltd. special ceramic coating,

developed thermal spray technology as well

as manufacturing plasma surface.

PORSCHE CERAMIC COMPOSITE DISC

BRAKES (PCCB)
This is manufactured

using a high vacuum

process.
The process
involves heating
carbon powder,
resins and carbon
fibres in a furnace at
1700 c

PROPERTIES OF PCCB
CDB with the involute cooling ducts for an

efficient cooling.
Offers braking response, fading stability,
weight & service life.
PCCB ensures maximum deceleration from
without 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 the
brakes also in wet weather.

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 Porsche100 to 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 even under high oxygen concentration.
Heavy commercial can be braked safely over long
distance without maintenance.

DISADVANTAGE
High initial cost and high cost of production.

APPLICATIONS
FORMULA-

1 cars 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 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 .

APPLICATION IN
PORSCHE 911

CDB IN UPPER CLASS LIMOUSINES

CDB IN SPORTS CARS

CONCLUSION
CDB

due to its advantages over the

conventional brake discs 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