SAE - Brake Design and Safety

Organization: SAE
Publication Date: 16 July 1999
Page Count: 542

The Second Edition continues to provide a systems approach to designing safer brakes. Consulting experts will find it a single reference in determining the involvement of brakes in accident causation.

Brakes system technology has attained a high standard of quality over the last two decades. Nearly all automobiles are now equipped with antilock brakes. Federal braking standards require commercial vehicles to use antilock brakes. Revolutionary innovative brake designs are not expected. Improvements in brake systems will only be achieved through basic research, the application of sound engineering concepts, and testing resulting in small yet important design changes.

The objective of the Second Edition is to assist the brake engineer in accomplishing his task to design safer brakes that can be operated and maintained safely. The brake expert will find all the analytical tools to study and determine the potential causes of brake failures. The Second Edition is expanded to cover all essential subjects including the mechanical and thermal analysis of disk brakes. Mistakes found in the First Edition were corrected.

I thank all those who have made valuable suggestions and comments and helped me to understand brakes better, in particular the many individuals who attended my Brake Design and Safety seminars.

The purpose of this book is to provide a systems approach to designing safer brakes. Much of the material presented was developed during my work as a brake design engineer, conducting automotive research, consulting as a brake expert, and teaching brake design.

The book is written for automotive engineers, technical consultants, accident reconstruction experts, and lawyers involved with the design of brake systems, the analysis of braking performance, and product liability issues. Junior engineers will benefit from the book by finding in one single source all essential concepts, guidelines, and design checks required for designing safer brakes.

Chapter 1 reviews basic stopping distance performance, design rules, and product liability factors.

In Chapter 2, drum and disc brakes are discussed. Brake torque computations are shown for different drum and disc brake designs.

Temperature and thermal stresses are analyzed in Chapter 3. Practical temperature equations are shown whenever possible.

Chapter 4 briefly reviews basic concepts involved in analyzing mechanical brake systems.

The operation and design of hydraulic brakes are discussed in Chapter 5.

Air brake systems and their components are discussed and analyzed in Chapter 6.

Brake force distribution, braking efficiency, optimum brake force distribution, and vehicle stability during braking for the single vehicle are analyzed in Chapter 7.

Car-trailer and commercial truck-trailer braking is discussed in Chapter 8.

Important elements of anti-lock braking performance and design are introduced in Chapter 9.

Brake failures are discussed in Chapter 10.