WORKING PRINCIPLEOF DISC BRAKE
When the driver steps on the brake pedal, the power is amplified by the brake booster (servo system) and changed into a hydraulic pressure (oil-pressure) by the master cylinder. The pressure reaches the brakes on the wheels via tubing filled with brake oil (brake fluid). The delivered pressure pushes the pistons on the brakes of the four wheels. The pistons in turn press the brake pads, which are friction material, against the brake rotors which rotate with the wheels. The pads clamp on the rotors from both sides and decelerate the wheels, thereby slowing down and stopping the vehicle.
β’ When the brake pedal is pressed, the high-pressure fluid from the master cylinder pushes the piston outward.
β’ The piston pushes the brake pad against the rotating disc.
β’ As the inner brake pad touches the rotor, the fluid pressure exerts further force and the caliper moves inward and pulls the outward brake pad towards the rotating disc and it touches the disc.
β’ Now both the brake pads are pushing the rotating disc, a large amount of friction is generated in between the pads and rotating disc and slows down the vehicle and finally, let it stop.
β’ When a brake pad is released, the piston moves inward, the brake pad away from the rotating disc. And the vehicle again starts to move.
When the driver steps on the brake pedal, the power is amplified by the brake booster (servo system) and changed into a hydraulic pressure (oil-pressure) by the master cylinder. The pressure reaches the brakes on the wheels via tubing filled with brake oil (brake fluid). The delivered pressure pushes the pistons on the brakes of the four wheels. The pistons in turn press the brake pads, which are friction material, against the brake rotors which rotate with the wheels. The pads clamp on the rotors from both sides and decelerate the wheels, thereby slowing down and stopping the vehicle.
β’ When the brake pedal is pressed, the high-pressure fluid from the master cylinder pushes the piston outward.
β’ The piston pushes the brake pad against the rotating disc.
β’ As the inner brake pad touches the rotor, the fluid pressure exerts further force and the caliper moves inward and pulls the outward brake pad towards the rotating disc and it touches the disc.
β’ Now both the brake pads are pushing the rotating disc, a large amount of friction is generated in between the pads and rotating disc and slows down the vehicle and finally, let it stop.
β’ When a brake pad is released, the piston moves inward, the brake pad away from the rotating disc. And the vehicle again starts to move.
TYPES OF DISC BRAKES
There are two types of disc brakes. One is called the "opposed piston type disc brake" which has pistons on both sides of the disc rotor, and the other is the "floating type disc brake" which has a piston on only one side. The floating type disc brakes are also called the sliding pin type disc brakes.
1. Opposed Piston Type Disc Brakes
The opposed piston type is a disc brake which has pistons on both sides of the disc rotors.
The opposed piston type disc brake features stable braking force as well as a high level of controllability.
The swept areas of the brake pads are enlarged to increase braking force, and here opposed piston types are favored. This is because of its advantage where the number of pistons can be increased to realize even distribution of pressure on the rotors from both sides. Depending on the size of the brake pads, there are several types, including the 4-pot type which has two pistons on each side for a total of four, and the 6-pot type which has three pistons on each side for a total of six.
2. Floating Type Disc Brakes
Floating type is a disc brake which has a piston on only one side and is also called the sliding type disc brake.
On the floating type disc brakes, the piston pushes the inner brake pad against the rotor when the brakes are engaged. This generates a reaction force that moves the caliper itself along with the slide pin, pushing the outer pad against the rotor to clamp it from both sides.
Many passenger car disc brakes are of the floating caliper type since this type has a relatively simple and lightweight construction, which allows for lower manufacturing costs.
Floating type disc brakes for commercial vehicles
Disc brakes are used mainly for passenger cars, but due to their consistent performance at higher speeds and resistance to brake fade, they are gradually spreading into the commercial vehicle segment, where drum brakes were traditionally chosen for their resistance against wear.
TYPES OF ROTOR
1. Smooth Rotors
Smooth rotors are identified by their flat, smooth surface. For most cars and trucks on the road, smooth rotors are original equipment (OE) because of their versatility for many driving conditions. The main benefit of smooth rotors is that they tend to wear evenly, helping your brake pads last longer. If you want to keep the smooth rotor but still go for the upgrade, look for premium metal that absorbs more heat.
2. Drilled or Dimpled Rotors
Drilled rotors are identified by the pattern of holes that have been drilled all the way through the rotor disc. Dimpled rotors are similar, though instead of holes there are dimples that have been drilled to the rotorβs minimum thickness level, retaining more structural integrity than a fully drilled rotor. These rotor types help the brake pads to better grip the rotor, giving it more initial bite and increasing stopping power.
*Note that drilled or dimpled rotors are typically found in combination with slotted rotors.
3. Slotted Rotors
Slotted rotors are recognized by carved lines found on the rotor. These carved slots help to cool the rotor during high-performance use. They also help to remove dirt and other debris from the disc and brake pad, helping to maintain consistent contact for more efficient braking. Slotted rotors are perfect for vehicles that see frequent, heavy towing.
4. Drilled/Dimpled and Slotted Rotors
Rotors that are both drilled (or dimpled) and slotted, while effective, are best for trucks that want the added aesthetic, such as those with wheels that have a more open design. Not only will they look great through an open-wheel, but the drilled holes assist with an initial bite while the slots are designed to remove dust and debris from between the rotor and brake pad.
There are two types of disc brakes. One is called the "opposed piston type disc brake" which has pistons on both sides of the disc rotor, and the other is the "floating type disc brake" which has a piston on only one side. The floating type disc brakes are also called the sliding pin type disc brakes.
1. Opposed Piston Type Disc Brakes
The opposed piston type is a disc brake which has pistons on both sides of the disc rotors.
The opposed piston type disc brake features stable braking force as well as a high level of controllability.
The swept areas of the brake pads are enlarged to increase braking force, and here opposed piston types are favored. This is because of its advantage where the number of pistons can be increased to realize even distribution of pressure on the rotors from both sides. Depending on the size of the brake pads, there are several types, including the 4-pot type which has two pistons on each side for a total of four, and the 6-pot type which has three pistons on each side for a total of six.
2. Floating Type Disc Brakes
Floating type is a disc brake which has a piston on only one side and is also called the sliding type disc brake.
On the floating type disc brakes, the piston pushes the inner brake pad against the rotor when the brakes are engaged. This generates a reaction force that moves the caliper itself along with the slide pin, pushing the outer pad against the rotor to clamp it from both sides.
Many passenger car disc brakes are of the floating caliper type since this type has a relatively simple and lightweight construction, which allows for lower manufacturing costs.
Floating type disc brakes for commercial vehicles
Disc brakes are used mainly for passenger cars, but due to their consistent performance at higher speeds and resistance to brake fade, they are gradually spreading into the commercial vehicle segment, where drum brakes were traditionally chosen for their resistance against wear.
TYPES OF ROTOR
1. Smooth Rotors
Smooth rotors are identified by their flat, smooth surface. For most cars and trucks on the road, smooth rotors are original equipment (OE) because of their versatility for many driving conditions. The main benefit of smooth rotors is that they tend to wear evenly, helping your brake pads last longer. If you want to keep the smooth rotor but still go for the upgrade, look for premium metal that absorbs more heat.
2. Drilled or Dimpled Rotors
Drilled rotors are identified by the pattern of holes that have been drilled all the way through the rotor disc. Dimpled rotors are similar, though instead of holes there are dimples that have been drilled to the rotorβs minimum thickness level, retaining more structural integrity than a fully drilled rotor. These rotor types help the brake pads to better grip the rotor, giving it more initial bite and increasing stopping power.
*Note that drilled or dimpled rotors are typically found in combination with slotted rotors.
3. Slotted Rotors
Slotted rotors are recognized by carved lines found on the rotor. These carved slots help to cool the rotor during high-performance use. They also help to remove dirt and other debris from the disc and brake pad, helping to maintain consistent contact for more efficient braking. Slotted rotors are perfect for vehicles that see frequent, heavy towing.
4. Drilled/Dimpled and Slotted Rotors
Rotors that are both drilled (or dimpled) and slotted, while effective, are best for trucks that want the added aesthetic, such as those with wheels that have a more open design. Not only will they look great through an open-wheel, but the drilled holes assist with an initial bite while the slots are designed to remove dust and debris from between the rotor and brake pad.
DISC BRAKE ROTOR MATERIALS
Brake rotors can be made of six different materials, each with its own advantages. Letβs take a look at each.
1. Cast Iron
This is the very definition of old school when it comes to a brake rotor. Itβs one or two pieces and gets the job done. In fact, itβs the most common material for brake rotors. The right design (usually two-piece) can even work well in a performance vehicle. However, itβs also the heaviest option, which affects the overall weight of your car and its handling, since that weight is right up there with your front wheels.
2. Steel
Steel has been the racerβs choice for years because a steel brake rotor is thinner, weighs less and handles heat better. The downside: Steel rotors arenβt as durable as some others, and warped rotors can cause noise and a pulsating pedal when you brake.
3. Layered Steel
Layering sheets of steel together and laminating them makes them resistant to the warping you might find in a straight steel brake rotor. Itβs a favorite of racers who donβt want frequent brake rotor replacement and repair, but manufacturers are currently only targeting professional racers and production is limited, so itβs not terribly common in passenger vehicle applications.
4. Aluminum
Aluminum brake rotors dissipate heat quickly, but they also melt at a lower temperature than other options. Aluminum is a favorite for motorcycles, which weigh less and are easier on the rotors when braking than a heavy car, truck or SUV.
5. High Carbon
These are iron, but with a lot of carbon mixed in. They can take a lot of heat and dissipate it quickly. The metallic content helps the rotor avoid cracking under high stress, and brake noise and vibration are reduced as well. The only downside is the price, which is significantly higher than straight iron or aluminum.
6. Ceramic
Whatβs your favorite super-car? Ferrari? Porsche? Lamborghini? Odds are itβs packing ceramic brake rotors. They offer the highest heat capacity (85 percent higher than cast iron) and superior dissipation, and they maintain a more consistent force and pressure as the temperature of the rotors rises. Ceramic is the highest-performance brake rotor available today.
ADVANTAGES AND DISADVANTAGES
Advantages
1. It is lighter than drum brakes.
2. It has better cooling ( because the braking surface is directly exposed to the air)
3. It offers better resistance to fade.
4. It provides uniform pressure distribution
5. Replacement of brake pads is easy.
6. By design, they are self-adjusting brakes.
Disadvantages
1. It is costlier than drum brakes.
2. Higher pedal pressure is required for stopping the vehicle. This brake system is installed with vacuum booster.
3. No servo action is present.
4. It is difficult to attach a suitable parking attachment.
Brake rotors can be made of six different materials, each with its own advantages. Letβs take a look at each.
1. Cast Iron
This is the very definition of old school when it comes to a brake rotor. Itβs one or two pieces and gets the job done. In fact, itβs the most common material for brake rotors. The right design (usually two-piece) can even work well in a performance vehicle. However, itβs also the heaviest option, which affects the overall weight of your car and its handling, since that weight is right up there with your front wheels.
2. Steel
Steel has been the racerβs choice for years because a steel brake rotor is thinner, weighs less and handles heat better. The downside: Steel rotors arenβt as durable as some others, and warped rotors can cause noise and a pulsating pedal when you brake.
3. Layered Steel
Layering sheets of steel together and laminating them makes them resistant to the warping you might find in a straight steel brake rotor. Itβs a favorite of racers who donβt want frequent brake rotor replacement and repair, but manufacturers are currently only targeting professional racers and production is limited, so itβs not terribly common in passenger vehicle applications.
4. Aluminum
Aluminum brake rotors dissipate heat quickly, but they also melt at a lower temperature than other options. Aluminum is a favorite for motorcycles, which weigh less and are easier on the rotors when braking than a heavy car, truck or SUV.
5. High Carbon
These are iron, but with a lot of carbon mixed in. They can take a lot of heat and dissipate it quickly. The metallic content helps the rotor avoid cracking under high stress, and brake noise and vibration are reduced as well. The only downside is the price, which is significantly higher than straight iron or aluminum.
6. Ceramic
Whatβs your favorite super-car? Ferrari? Porsche? Lamborghini? Odds are itβs packing ceramic brake rotors. They offer the highest heat capacity (85 percent higher than cast iron) and superior dissipation, and they maintain a more consistent force and pressure as the temperature of the rotors rises. Ceramic is the highest-performance brake rotor available today.
ADVANTAGES AND DISADVANTAGES
Advantages
1. It is lighter than drum brakes.
2. It has better cooling ( because the braking surface is directly exposed to the air)
3. It offers better resistance to fade.
4. It provides uniform pressure distribution
5. Replacement of brake pads is easy.
6. By design, they are self-adjusting brakes.
Disadvantages
1. It is costlier than drum brakes.
2. Higher pedal pressure is required for stopping the vehicle. This brake system is installed with vacuum booster.
3. No servo action is present.
4. It is difficult to attach a suitable parking attachment.
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Huge Ship Shaft Forging and Machining Process https://youtu.be/lK9W9SFoFTI
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Huge Ship Shaft Forging and Machining Process
Forging is a manufacturing process involving the shaping of metal using localized compressive forces. The blows are delivered with a hammer (often a power hammer) or a die. Forging is often classified according to the temperature at which it is performed:β¦
Valve Clearance Adjustment - Tappet Setting | 3 cylinder MDI engine https://www.youtube.com/watch?v=NUsXKAAj0cQ
Automotive Tech π:
INJECTION SYSTEM
β Fuel injector is an electronically controlled mechanical device that is responsible for spraying (injecting) the right amount of fuel at a right time into the engine so that a suitable air/fuel mixture is created for optimal combustion.β
The technology was created in the early 20th century and implemented on diesel engines first. By the final third of the 20th century, it had also become popular among regular gasoline engines.
The electronic control unit (ECU at engine management system) determines the precise amount and specific timing of required gasoline (petrol) dose for every cycle, by collecting information from various engine sensors. So, the ECU sends a command electrical signal of the correct duration and timing to the fuel injector coil. In that way opens the injector and allows petrol to pass through it into the engine.
The one terminal of the injector coil is directly supplied by 12 volts which are controlled by the ECU, and the other terminal of the injector coil is open. When ECU determined the exact amount of fuel and when to inject it, activates the appropriate injector by switching the other terminal to the ground (mass, i.e. negative pole).
COMPONENTS
The objectives of the fuel injection system are to meter, atomize and distribute the fuel throughout the air mass in the cylinder. At the same time, it must maintain the required air-fuel ratio as per the load and speed demand on the engine.
1. Pumping elements:
To move the fuel from the fuel tank to the cylinder.
2. Metering elements:
To measure the supply of the fuel at the rate demanded by speed and load conditioning on the engine
3. Metering control:
To adjust the rate of the metering elements for change in load and speed of the engine.
4. Mixture control:
To adjust the ratio of the fuel and air as demanded by the load and speed.
5. Distributing elements:
To divide the metered fuel equally among the cylinder.α§
6. Timing control:
To fix the start and stop of the fuel-air mixing process.
INJECTION SYSTEM
β Fuel injector is an electronically controlled mechanical device that is responsible for spraying (injecting) the right amount of fuel at a right time into the engine so that a suitable air/fuel mixture is created for optimal combustion.β
The technology was created in the early 20th century and implemented on diesel engines first. By the final third of the 20th century, it had also become popular among regular gasoline engines.
The electronic control unit (ECU at engine management system) determines the precise amount and specific timing of required gasoline (petrol) dose for every cycle, by collecting information from various engine sensors. So, the ECU sends a command electrical signal of the correct duration and timing to the fuel injector coil. In that way opens the injector and allows petrol to pass through it into the engine.
The one terminal of the injector coil is directly supplied by 12 volts which are controlled by the ECU, and the other terminal of the injector coil is open. When ECU determined the exact amount of fuel and when to inject it, activates the appropriate injector by switching the other terminal to the ground (mass, i.e. negative pole).
COMPONENTS
The objectives of the fuel injection system are to meter, atomize and distribute the fuel throughout the air mass in the cylinder. At the same time, it must maintain the required air-fuel ratio as per the load and speed demand on the engine.
1. Pumping elements:
To move the fuel from the fuel tank to the cylinder.
2. Metering elements:
To measure the supply of the fuel at the rate demanded by speed and load conditioning on the engine
3. Metering control:
To adjust the rate of the metering elements for change in load and speed of the engine.
4. Mixture control:
To adjust the ratio of the fuel and air as demanded by the load and speed.
5. Distributing elements:
To divide the metered fuel equally among the cylinder.α§
6. Timing control:
To fix the start and stop of the fuel-air mixing process.
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The Speech that Inspired 1,200,000 People : WHY? vs WHY NOT? Jim John
The Speech that Inspired 1,200,000 People : WHY? vs WHY NOT? Jim John
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