Brake Pipe Design
Brake Pipe Design:
Steel
|
Cu Alloy
|
Cu-Ni-Si Alloy
|
Remark
|
|
Lower Yield Strength
N/mm2
|
250
|
410
|
600
|
Though driver never apply
full weight (75Kg) on brake. However system must be designed for worst case.
|
Pipe Thickness mm
|
3
|
3
|
3
|
|
OD mm
|
10
|
10
|
10
|
|
Burst Pressure in N/mm2
|
150
|
246
|
360
|
|
Burst Pressure in Bar
|
1500
|
2460
|
3600
|
|
#Pressure Generated by Driver Bar
|
212
|
212
|
212
|
|
Factor of safety
|
7
|
11.6
|
16.9
|
(CU Alloy: Zirconium Copper Cold
Drawn Aged; Cu-Ni-Si Alloy: Copper Nickel Silicon Aged)
Burst Pressure = 2 * Material
Strength * Pipe Wall Thickness / Pipe OD
#Conclusion:
Refer Design 5; A 75 Kg Driver (at
750N applied pedal force) can create up to 212 bar pressure in pipe with 10 mm Calipers
piston, 45mm Master cylinder piston and Pedal Ratio 5.
Total Mass Kg
|
Total Weight N
|
#Height COG
|
#Wheel Base mm
|
#Front Axle to COG
|
load on Rear Axle N
|
X
|
ψ
|
M
|
W (N)
|
HCOG
|
L (mm)
|
Lm mm
|
Frear
|
CG/WB
|
Frear/ W
|
545.0000
|
5346.45
|
350.00
|
2700.000
|
1900.0
|
3762.3
|
0.12963
|
0.70370
|
Rear calliper pushout pressure
|
Front/rear pad-disc brake factor
|
**Pedal lever ratio
|
Lever/master
cylinder effici
|
Bias ratio
|
Master cylinder bore diameter
|
Master cylinder Area m2
|
**Front/rear calliper piston diameter
mm
|
Por
|
Bff
|
Lp
|
np
|
Br
|
Dmm
|
Amc
|
Dcalpis mm
|
0.00000
|
0.76000
|
5.00000
|
0.80000
|
0.80000
|
10.00000
|
0.00008
|
45.00000
|
No of pistons in each front calliper
|
No of front callipers used
|
Front rear calliper cylinder effici
|
Mean eff radius of front disc
|
Radius of the front tyre m
|
**Front/rear calliper piston diameter
m
|
Front calliper pushout pressure
|
Mean effective radius of rear braking disc m
|
nf
|
Nf
|
ncf
|
rf
|
Rf
|
Dcf
|
Pof
|
rr
|
2.00
|
2.00
|
0.98
|
0.25000
|
0.33
|
0.045
|
0.00
|
0.25
|
deceleration (g)
|
OPT F(N)
|
OPT R(N)
|
**Caliper Piston Area
|
0.00159
|
|||
-3.30000
|
0.43389
|
-3.73389
|
Aplied pedal force (N)
|
ACTUAL F
|
ACTUAL R
|
Pl F Pressure
|
Plr Pressure
|
-3.00000
|
0.27778
|
-3.27778
|
0.00000
|
0.00000
|
0.00000
|
0.00000
|
0.00000
|
-2.70000
|
0.14500
|
-2.84500
|
25.00000
|
0.47491
|
0.37993
|
707714.08351
|
566171.26681
|
-2.28570
|
0.00000
|
-2.28570
|
53.00000
|
1.00681
|
0.80545
|
1500353.85704
|
1200283.08563
|
-2.00000
|
-0.07407
|
-1.92593
|
70.00000
|
1.32975
|
1.06380
|
1981599.43383
|
1585279.54706
|
-1.80000
|
-0.11333
|
-1.68667
|
100.00000
|
1.89965
|
1.51972
|
2830856.33404
|
2264685.06723
|
-1.50000
|
-0.15278
|
-1.34722
|
125.00000
|
2.37456
|
1.89965
|
3538570.41755
|
2830856.33404
|
-1.20000
|
-0.16889
|
-1.03111
|
150.00000
|
2.84947
|
2.27958
|
4246284.50106
|
3397027.60085
|
-0.90000
|
-0.16167
|
-0.73833
|
175.00000
|
3.32438
|
2.65950
|
4953998.58457
|
3963198.86766
|
-0.60000
|
-0.13111
|
-0.46889
|
200.00000
|
3.79929
|
3.03943
|
5661712.66808
|
4529370.13447
|
-0.30000
|
-0.07722
|
-0.22278
|
225.00000
|
4.27420
|
3.41936
|
6369426.75159
|
5095541.40127
|
0.00000
|
0.00000
|
0.00000
|
250.00000
|
4.74912
|
3.79929
|
7077140.83510
|
5661712.66808
|
0.30000
|
0.10056
|
0.19944
|
275.00000
|
5.22403
|
4.17922
|
7784854.91861
|
6227883.93489
|
0.60000
|
0.22444
|
0.37556
|
300.00000
|
5.69894
|
4.55915
|
8492569.00212
|
6794055.20170
|
0.90000
|
0.37167
|
0.52833
|
325.00000
|
6.17385
|
4.93908
|
9200283.08563
|
7360226.46851
|
1.20000
|
0.54222
|
0.65778
|
350.00000
|
6.64876
|
5.31901
|
9907997.16914
|
7926397.73531
|
1.50000
|
0.73611
|
0.76389
|
375.00000
|
7.12367
|
5.69894
|
10615711.25265
|
8492569.00212
|
1.80000
|
0.95333
|
0.84667
|
400.00000
|
7.59858
|
6.07887
|
11323425.33616
|
9058740.26893
|
2.10000
|
1.19389
|
0.90611
|
425.00000
|
8.07350
|
6.45880
|
12031139.41967
|
9624911.53574
|
2.40000
|
1.45778
|
0.94222
|
450.00000
|
8.54841
|
6.83873
|
12738853.50318
|
10191082.80255
|
2.70000
|
1.74500
|
0.95500
|
475.00000
|
9.02332
|
7.21866
|
13446567.58670
|
10757254.06936
|
3.00000
|
2.05556
|
0.94444
|
500.00000
|
9.49823
|
7.59858
|
14154281.67021
|
11323425.33616
|
3.30000
|
2.38944
|
0.91056
|
525.00000
|
9.97314
|
7.97851
|
14861995.75372
|
11889596.60297
|
3.60000
|
2.74667
|
0.85333
|
550.00000
|
10.44805
|
8.35844
|
15569709.83723
|
12455767.86978
|
3.90000
|
3.12722
|
0.77278
|
575.00000
|
10.92297
|
8.73837
|
16277423.92074
|
13021939.13659
|
4.20000
|
3.53111
|
0.66889
|
600.00000
|
11.39788
|
9.11830
|
16985138.00425
|
13588110.40340
|
4.44444
|
3.87745
|
0.56699
|
625.00000
|
11.87279
|
9.49823
|
17692852.08776
|
14154281.67021
|
4.80000
|
4.40889
|
0.39111
|
650.00000
|
12.34770
|
9.87816
|
18400566.17127
|
14720452.93701
|
5.10000
|
4.88278
|
0.21722
|
675.00000
|
12.82261
|
10.25809
|
19108280.25478
|
15286624.20382
|
5.42857
|
5.42857
|
0.00000
|
700.00000
|
13.29752
|
10.63802
|
19815994.33829
|
15852795.47063
|
5.70000
|
5.90056
|
-0.20056
|
725.00000
|
13.77244
|
11.01795
|
20523708.42180
|
16418966.73744
|
6.00000
|
6.44444
|
-0.44444
|
750.00000
|
14.24735
|
11.39788
|
21231422.50531
|
16985138.00425
|
Above last row 4th column and 7th column ( Take 8th in case it has higher pressure in pipe for material selection, thickness, toughness, strength criteria). 4th column is nothing but the force by driver so for 75 kg weight driver max force on brake will be 75 X g or 750 Kg.m/sec2 approximately. 7th column is pressure in front pipe and 8th column is pressure in rear brake pipe. this pipe will burst when brake is applied if wrong specification is selected.
750 N ( 75 Kg weight of driver) worst case can generate 21231422/10000 bar or 212 bar pressure so brake pipe must not leak, fail, bulge below this pressure.
