The quest for an engine to increase mileage has started before many years. Many automobile manufacturing industries are doing more research on how to increase mileage of vehicle. In today’s automobile competition every manufacturer is focusing on weight reduction of vehicle by considering this objective, this paper focuses on providing alternative material. The objective of the present work is to optimize weight reduction to increase mileage of vehicle. Saving grams at different parts in a car helps us in saving some kilograms at the end of the design. Also the main material like polyimide for automobile component manufacturing can be the best alternative solution in all respect. The focus of this paper is on weight reduction of master cylinder. For modeling and analysis PRO-E and ANSYS is used. The results obtained are comparatively better than existing materials and polyimide can be the alternative solution for automotive component.

1. International Journal of Research In Science & Engineering e-ISSN: 2394-8299
Volume: 1 Issue: 1 p-ISSN: 2394-8280
IJRISE| www.ijrise.org|editor@ijrise.org [10-14]
MODELING ANALYSIS AND OPTIMIZATION OF MASTER CYLINDER
OF HYDRAULIC BRAKING SYSTEM
__________________________________________________________________
Manish Digambar Toprakwar1
,Ketan W. Adwe2
,Shubham S. Golhar3
1
Student, Mechanical Engineering, JDIET, Yavatmal,Maharashtra,India,toprakwar07@gmail.com
2
Student,Mechanical Engineering, JDIET, Yavatmal, Maharashtra, India,Ketanadwe110@gmail.com
2
Student, Mechanical Engineering, JDIET, Yavatmal, India, Shubhamgolhar11@gmail.com
_____________________________________________________________________________________
ABSTRACT
The quest for an engine to increase mileage has started before many years. Many automobile
manufacturing industries are doing more research on how to increase mileage of vehicle. In today’s
automobile competition every manufactureris focusing on weight reduction of vehicle by considering
this objective, this paper focuseson providing alternative material. The objective of the present work is
to optimize weight reduction to increase mileage of vehicle. Saving grams at different parts in a car
helps us in saving some kilograms at the end of the design. Also the main material like polyimide for
automobile component manufacturing can be the best alternative solution in all respect. The focus of
this paper is on weight reduction of master cylinder.For modeling and analysis PRO-E and ANSYS is
used. The results obtained are comparatively better than existing materials and polyimide can be the
alternative solution for automotive component.
Keywords: Hydraulic braking system; Master cylinder; Polyimide, ANSYS.
---------------------------------------------------------------------------------------------------------------------
1. INTRODUCTION
Braking system is a means of converting momentum into heat energy by creating friction in the wheel brakes.
The braking system which works with the help of hydraulic principles is known as hydraulic braking systems. The
braking system used most frequently operates hydraulically, by pressure applied through a liquid. These are the foot
operated brakes that the driver normally uses to slow or stop the car. Hydraulics is the use of a liquid under pressure
force or motion, or to increase an applied force. Our special interest in hydraulics is related to the actions in
automotive systems that result from pressure applied to a liquid. This is called hydraulic pressure. Since liquid is not
compressible, it can transmit motion. A typical braking system includes two basic parts. These are the master
cylinder with brake pedal and the wheel brake mechanism. The other parts are the connecting tubing, or brake lines,
and the supporting arrangements. Braking action starts at the brake pedal. When the pedal is pushed down then
brake fluid is sent from the master cylinder to the wheels. At the wheels, the fluid pushes brake shoes, or pads,
against revolving disks or drums. The friction between the stationary pads or shoes and the revolving drums or disks
slows and stops them.
1.1 Problem Statement
The quest for an engine to increase mileage has started before many years. Many automobile
manufacturing industries are doing more research on “How to increase mileage of vehicle?”
The most important area of research is,
a) To increase engine efficiency.
b) To reduce weight of vehicle
1.2 Objective
In this era of automobile competition every manufacturer is focusing on weight reduction of vehicle by
considering this objective, my work focus on providing alternative material for heavy material like cast iron,
aluminium. The main objective of this work is to use material for automobile component manufacturing which will
reduce weight of vehicle. Material of properties such as lightweight, strong, high heat resistance, thermal stability,

2. International Journal of Research In Science & Engineering e-ISSN: 2394-8299
Volume: 1 Issue: 1 p-ISSN: 2394-8280
IJRISE| www.ijrise.org|editor@ijrise.org [10-14]
good chemical resistance, are use instead of cast iron, aluminium etc.Use of such material for dumper, door panel,
fuel system, car dash board, carburettor component, etc. Will not only reduce weigh but also result in increase in
mileage.
2. MATERIALANDMETHODS
2.1 Polyimide
Polyimide is a very versatile material. It offers a great combination of properties such as lightweight, strong, high
heat resistance, as well as stiffness and flexural retention. Polyimide (sometimes abbreviated PI) is a polymer
of imide monomers. Since 1955 polyimides have been in mass production. With their high heat-resistance,
polyimides has many applications in demanding rugged organic materials, e.g. various military roles, high
temperature fuel cells, displays. Polyimides are known for good chemical resistance, thermal stability and excellent
mechanical properties, Polyimides are also inherently resistant to flame combustion and do not usually need to be
mixed with flame retardants. Polyimide also used in a wide variety of applications including automobile parts,
packaging, labelling, stationery, plastic parts and reusable containers, textiles. Strength and heat and chemical
resistance are so great that these materials often replace glass and metals, such as steel aluminium.
2.2 Properties ofPolyimide
2.2.1 Machining Properties
The machine ability of polyimide is excellent. It may be processed on any standard machine shop equipment.
2.2.2 Density And Specific Gravity
Specific gravity, similar to relative density, is a ratio of the weight of a certain volume of material to an
equal volume of water at 23°c. Determining the specific gravity of a material is done by weighing the sample in air
then weighing it again, submerged in distilled water. These two weights will be entered into a formula where the
specific gravity can be found. Relative density/specific gravity of polyimide is 1.43g/cm3
.
2.2.3 Tensile Strength
Tensile strength is determined through tensile testing, which is a measurement of how much force a plastic
can withstand before fracturing or breaking. Throughout the tensile testing, information such as ductility or
brittleness of a material is revealed. This information is used when designing parts to be absolutely positive that the
part will withstand all environmental forces it will encounter. A stress vs. Strain graph, created fromthe tensile test,
is commonly used to find out the materials tensile strength at its yielding point and its tensile modulus. Tensile or
yield strength of polyimide is 231mpa at 230
c and 139mpa at 2000
c.
2.2.4 Tensile Modulus
The tensile modulus is a ratio of stress to elastic strain in tension. The tensile modulus of different resins
may be acquired through tensile test. Tensile modulus of polyimide is 2.5g pa
2.2.5 Hardness
When measuring the hardness of materials, the Rockwell hardness test is used. On a hardness testing
machine the hardness is determined by penetrating the material with an indicator. The further the indicator
penetrates the sample, the larger the number measured, and the harder the material. Hardness of polyimide is 95-120
(r)
2.2.6 Thermal Conductivity
Thermal conductivity is the rate at which heat is transferred through a section of material. When it comes to
materials which are exposed to the most extreme temperatures, the measure of heat flow through a material is a
testing essential. The molecular make-up, thickness, and density of a material, all directly relate to its thermal
conductivity. Thermal conductivity of polyimide is 0.12w/m k
2.3 MODELINGUSINGPRO-E
Pro-E is a program that is used to create precision three dimensional computer models. The 3-
Dimenssional parts created on Pro-E use a technique known as solid modeling. Other important descriptors used to
categorize Pro-E include: feature-based, associative, and constraint (or parametric)-based. Pro-E is a fully
parametric program, This means that the geometry of features (e.g., holes, slots) on a part have to be fully specified
in terms of size, shape, location and orientation. This specification allows the user to write equations (i.e., relations)
which describe how features on individual parts or multiple parts should relate to each other. For e.g. in an engine, if
the diameter of the piston is decreased or increased, the corresponding engine block is automatically modified to
match the specifications of the new piston. The specifications of the standard cylinder used for the present study are
given in the following table 1.

3. International Journal of Research In Science & Engineering e-ISSN: 2394-8299
Volume: 1 Issue: 1 p-ISSN: 2394-8280
IJRISE| www.ijrise.org|editor@ijrise.org [10-14]
Table 1: Dimension of master cylinder
Figure 1 : Model of Master cylinder using PRO-E
2.3.1 Volume & Mass For Aluminium Master Cylinder
The formulae and calculations for weight of the aluminium master cylinder are given below.
1. Volume V = πR2
h
V = 1.046×10-4 m3
2. Mass m = density × volume
m = 0.282 kg
2.3.2Volume & Mass For polyimide Master Cylinder
The overall weight of the plastic master cylinder is measured, which is 0.355kg. The formulae and calculations for
weight of the plastic master cylinder are given below.
1. Volume V = πR2
h
V = 1.046×10-4 m3
2. Mass m = density × volume
m = 0.149 kg
Table 2: Comparing The Results
Name Symbol Units Dimension
Cylinder outer diameter Do mm 34.8
Cylinder inner diameter Di mm 26.8
Thickness of cylinder T mm 4
Height of cylinder H mm 110
Type of cylinder Mass kg Density kg/m3
Aluminium 0.282 2700
polyimide 0.149 1430

4. International Journal of Research In Science & Engineering e-ISSN: 2394-8299
Volume: 1 Issue: 1 p-ISSN: 2394-8280
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3. RESULTS AND DISCUSSION
Analysis of Master cylinder of hydraulic braking system is done by using ANSYS software. For that material
properties are as follows
Table 3: Properties of material
Figure 2: meshed model for brake master cylinder
Figure 3: Stress intensity on aluminium master cylinder
Material Young’s Modulus Poisson’s Ratio
Aluminium 70000 N/mm2 0.3
Polyimide 2500 N/mm2 0.34

5. International Journal of Research In Science & Engineering e-ISSN: 2394-8299
Volume: 1 Issue: 1 p-ISSN: 2394-8280
IJRISE| www.ijrise.org|editor@ijrise.org [10-14]
Figure 4: Stress intensity on polyimide master cylinder
The maximum stress acting on the surface of aluminium master cylinder is 69.81 N/mm2
and the maximum
stress acting on the surface of polyimide master cylinder is 69.39 N/mm2
for a pressure of 4 N/mm2
.The stress
induced in polyimide master cylinder is slightly greater than the stress in aluminium master cylinder but it is less
compare to the ultimate strength of that material.
CONCLUSION
In this paper of modeling analysis and optimization of master cylinder of hydraulic breaking system are
performed and conclude that the polyimide is an alternative material for aluminium which can be used in automobile
manufacturing.
 The weight of master cylinder made up of polyimide i.e. 0.149 kg is less than master cylinder made up of
Aluminium i.e. 0.282 kg.
 The stress induced in aluminium master cylinder is more than the stress induced in master cylinder made up of
polyimide material as well as the induced stress in polyimide material is very less compared to ultimate strength
of that material.
REFERENCES
[1] “Dupont Kapton Polyimide Film General Specifications, Bulletin GS-96-7”.
http://www.dupont.com/kapton/general/H-38479-4.pdf
[2] J. Reddaiah, Dr. G. Harinath Gowd, S. Praveen Kumar, V. Vishnuvardhan, “Design & Analysisof Master
Cylinder of Hydraulic Braking System Using ANSYS”, IJITEE, ISSN: 2278-3075, Volume-3,Issue- 7,
December 2013.
[3] Khurmi S.R. and Gupta K.J, “Machine Design”, S.chand publication page no.18
[4] Walter W. Wright and Michael Hallden-Abberton "Polyimides" in Ullmann's Encyclopedia of Industrial
Chemistry, 2002, Wiley-VCH, Weinheim. doi:10.1002/14356007.a21_253 Web link,
http://www.wilwood.com/MasterCylinders /MasterCylinderList.aspx? group = Aluminum%
20Tandem%20Master%20Cylinder.