Technical focus on…The brake for the new F1 season
date
24 March 2017

category
Racing world

 

Technical focus on…

The brake for the new F1 season

Dealing with wide tires will allow F1 cars to develop greater braking torques,  Brembo engineers have focused on the redesign of the individual elements composing the systems: starting from the brake calipers, which have to adapt to the increased thickness of the disc that has grown from 28mm to 32mm.

Over 1400 ventilation holes

The increased size of the carbon discs has allowed to strengthen the design in the drop zone, increasing the braking capacity. Furthermore, the greater thickness allows more space for the ventilation holes, causing further evolution of the braking cooling system.

Even this year, the teams supplied by Brembo can count on a personalized cooling design. In this way, there will be an average increase of about 200 ventilation holes for each disc, compared to over 1,200 in 2016 and a consequent increase in heat dissipation, remembering that the temperature of the discs in F1 can exceed 1,000°C during braking.

Deceleration over 6g ventilation holes

Thanks to the exchange of information with the teams, simulations related to the behaviour of the new cars and to the dynamic bench tests, the engineers have been able to estimate an increase of the braking torque of around 25%, which will bring the braking to over 6g deceleration. The cars will be able to transmit greater braking force on the ground in the shortest time, with a possible decrease in the average lap time spent braking.

New tailor made caliper

Formula One requires an extensive customization of braking systems resulting in the different design solutions of F1 cars. Each team supplied by Brembo requires a brake system that is increasingly "tailor-made", closely integrated with the design of the car and subject to continual development throughout the season.

It is also for this reason that the brake calipers have been totally redesigned for each supplied team, to integrate with the aerodynamic solutions studied by each team, trying to keep optimal lightness and stiffness, despite the increased size of the disc.

Furthermore, Brembo continues the development work of the individual components of the Brake By Wire system. The engineers further broadened their skills, designing various components of BBW according to the demands of individual team and working further on the integration and on the miniaturization of various elements. As happened in 2016, the majority of the teams will opt for rear discs of small diameter, in line with the energy required, deriving from the recovery system. For certain teams, the Company developed only some BBW components, while for others Brembo conducted more extensive work concerning the entire system: from the simulator on which operates the rear brake master cylinder, to the actuator controlled by the control unit and which drives calipers on the rear axle, to the safely valves system that controls the switching in case of system malfunction.

Significant decrease in the brake system wear level with CER

During winter technicians worked on carbon brake disc material (named CER) to improve the performance continuity and the operating range. Thanks to an effective heat conduction, CER has considerably reduced wear. CER reduces the warm up time needed to reach operating temperature, offers a broader operating range in terms of both pressure and temperature, together with linear friction characteristics. All of these features contribute to giving the driver precise control over the braking system. Furthermore, the incredibly low wear rate of this material ensures consistent, repeatable performance from the start of the race to the chequered flag.

 

Numbers & curiosities

In a complete season, on average Brembo supplies the following materials to each team running 2 race cars:

10 sets of calipers

140-240 discs

280-480 brake pads

14 hours (or more) need for the manufacture of each brake calipers in aluminium/lithium with the perfect balance between weight and stiffness

2500 km the frequency of the revisions of brake calipers

800 km the track mileage recommended by Brembo for the use of brake discs