Design and analysis of brake system for FSAE race car

Abstract

The objective of this research paper is to design, simulate and compare components of a race car braking system. The Racecar is an FSAE car that is designed around the rules and regulations of the FSAE rulebook, the main aim of this project is to make components lightweight and improve their performance as compared to their OEM counterparts. The braking system involves the mathematical calculation of pedal ratio, brake torque, heat generated in brake discs, and required clamping force using MATLAB to achieve peak deceleration after which these values would be used to design and simulate the components. The paper presents some innovative new ideas applied in an FSAE car and also involves designing techniques like topology optimization which was done using Altair inspire. Finally, all the components were designed in Solidworks, and simulations like Factor of safety, von mises stress, and strain were performed using ANSYS 18.1. The paper also compares the work of other authors as well and explains the differentiating factors between our and their design.