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Formula SAE Hydraulic Brake System
- Project Title & Role:
Formula SAE Hydraulic Brake System — Brake System Lead (Vice-Captain, Team Eclipse Racing) - Problem Statement:
Competition car required a lightweight, tunable brake system capable of achieving 0.9 g deceleration with balanced lockup. - My Solution:
- Designed dual-master cylinder system with adjustable balance bar.
- Ran MATLAB studies for sizing, ANSYS FEA for pedal/rotor stress.
- Used AL 6061-T6 pedal box and SS420 floating rotors.
- Validated with on-car DAQ testing.
- Key Deliverables/Outcomes:
- Achieved target deceleration with bias control (51:49).
- Pedal system FoS > 3.5, weight saving ~2.25 kg.
- Competed successfully at SAE SUPRA 2019 and Formula Bharat 2021.
- Visuals:
- CAD of pedal box assembly.
- Rotor + bobbin design.
- On-track braking test photo.
