Design, Fabrication & Testing of Braking System & Wheel Hubs of FSAE Vehicle

The following project encompasses the Design of 2019 Vidyavardhini’s College of Engineering And Technology FSAE vehicle braking system and wheel hubs. The objective of the system is to convert the kinetic energy of the vehicle into thermal energy, allowing the vehicle to decelerate optimally and safely using a hydraulic braking system. The results and findings of the proceeding report rendered a symmetrical front and unsymmetrical rear braking system. An optimized pedal box was designed consisting of three pedals, (throttle, brake and clutch), twelve mounting tabs for the three pedals and master cylinders, and two electrical sensors supports (one for the inertia switch and the other for the emergency stop switch). The pedal box was optimized for minimal mass and satisfied the design criteria (later defined in the text). Later custom brake disc and hubs were designed based on the optimal material choice, after analyzing thermal effects.