© 2019 JETIR April 2019, Volume 6, Issue 4 www.jetir.org (ISSN-2349-5162) JETIRBB06073 Journal of Emerging Technologies and Innovative Research (JETIR) www.jetir.org 345 Design And Analysis of Disc Brake Caliper for Centreless Wheel Assembly of FS vehicle Atharva Kulkarni 1 , Nikhil Bhojwani 2 , Prajakta Shewale 3 , Pratik Ahire 4 ,Dr.Nitin Sherje 5 Mechanical Department, Smt. KashibaiNavale College of Engineering Abstract—Effective braking is a critical factor determining the performance and drivability of any vehicle. Brake caliper being the heart of a braking system, the whole system is built considering its strength. An optimized design of a brake caliper thereby ensures reduced size of wheel assembly, reduced weight and effective braking. The analysis is further used to identify the critical locations of low stiffness on the brake caliper and also aimed at evaluating the performance of brake caliper under severe braking conditions. Hence best suitable design is suggested based on the performance and strength criteria. This paper studies a conceptual design of a brake caliper for a Formula Student (F.S.) vehicle, primarily focusing on reducing the size and weight without compromising its strength and stiffness. 3D modelling of brake caliper is created in Solidworks and analysed for stress, deformation and temperature distribution in ANSYS Workbench Keywords—Centerless Assembly, Bore Diameter, Piston Seal, Seal Groove Geometry, Piston Retraction. I. INTRODUCTION A brake system works by converting kinematic energy into thermal energy, which is absorbed by the brake system (mainly rotor) and dissipated into surrounding structures and atmosphere. Upon pressure application with disc rotating, the piston is pushed forward to press the inner pad against the rotor. Floating and Fixed calipers are the two categories of brake calipers and by extension they determine the categories of disc brake itself. A. How the Floating or Sliding Caliper works A caliper bracket is solidly mounted and the caliper itself within that bracket isn't solidly mounted so it can slide left and right via pins and bushings on the bracket. A piston on the inner side of the disc pushes that brake pad as if to move the disc but because the disc can't slide, the force pulls the sliding caliper with another brake pad unto the other side of the disc. The advantages of the floating caliper is that it’s cheaper and lighter than the fixed caliper as it uses less parts and is more compact. B. Working of Fixed Caliper: The fixed caliper comprises two half calipers (flange and cover), each of which have one or two brake pistons). Both parts, firmly screwed together (expansion screws) and connected by the so-called channel bore, make up the “fixed caliper”. This is bolted to the wheel suspension of the vehicle (kingpin, axle flange) or in the case of inboard brakes, to the gearbox. When the brake is operated (build-up of hydraulic pressure), two or four brake pistons respectively force the pads to simultaneously make contact with the rotating brake discs on each side (braking position). The brake pads are guided and supported in the so-called caliper housing. The caliper housing must be clean and undamaged, in order to prevent the brake pads from jamming or seizing up due to rust . If this happened, it would be impossible to press the pads against the brake discs (no braking effect). When the pressure falls (upon completion of braking) the brake pistons are retracted due to the “rollback” – as described under “Function of the disc brake” – and the brake pads are forced against the piston by the expansion spring. The brake disc can now rotate freely because of the clearance. To compensate for tapered brake pad wear on the leading edge, some fixed calipers have a “piston shoulder”. This piston shoulder must always be in its specified position with respect to the leading edge (observe garage manual instructions). If this is not the case, it cannot fulfil its function and it can lead to unpleasant brake noise. If the piston is not aligned correctly, it must be returned to the specified position using piston turning pliers and the prescribed piston gauge. Floating and Fixed Caliper