This document discusses the design and computational fluid dynamics (CFD) analysis of a custom hydraulic braking system compared to an original equipment manufacturer (OEM) system. It includes sections on the background of braking systems, classification of different types, design procedure, stress calculations and analysis, and conclusions. The objective is to calculate brake fluid pressure at the caliper using CFD and compare it to the OEM model. The custom design uses independent hydraulic circuits for each wheel to maintain braking power even if one circuit leaks. CFD analysis found the pressure at the caliper was lower than the OEM system.
A disc brake is a type of brake that uses the calipers to squeeze pairs of pads against a disc or rotor to create friction. This action slows the rotation of a shaft, such as a vehicle axle, either to reduce its rotational speed or to hold it stationary. The energy of motion is converted into waste heat which must be dispersed. Disc brake system is widely used on front wheels in mid range two wheeler such as - commuter and sports bikes. The Disc brake system is used on the front wheels of most hatchback cars, entry level sedans and MUVs whereas, it is also widely used on both front and rear wheels of high end cars and SUVs in combination with hydraulic vacuum brake actuating systems. Vikrant Yadav | Pankaj Yadav "Overview of Disc Brake" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-4 | Issue-4 , June 2020, URL: https://www.ijtsrd.com/papers/ijtsrd31530.pdf Paper Url :https://www.ijtsrd.com/engineering/automotive-engineering/31530/overview-of-disc-brake/vikrant-yadav
This document provides an overview of disc brakes, including:
- Disc brakes work by using brake pads in a caliper to create friction against a rotor attached to the wheel, slowing the wheel's rotation.
- Key parts include the master cylinder, brake pedal, caliper, rotor, and brake pads. The caliper houses the pads and presses them against the rotor when braking is applied.
- Disc brakes offer better performance than drum brakes, as they are less affected by weather and do not get clogged. However, they also have higher costs and complexity.
In the existing automobile market which is growing, the competition for better automobile in climbing up enormously. The racing fans involved will surely know the importance of a good brake system not only for safety but also for staying competitive in every race though Brake is the key factor for safety. Braking is a process which converts the kinetic energy of the automobile into mechanical energy for arresting the rotation of the road wheels which must be dissipated in the form of heat.
This document discusses the key components of drum brake systems, including wheel cylinders, brake shoes, brake linings, servo action, brake self-adjusters, and drums. It explains that wheel cylinders contain pistons that apply force to the brake shoes, while return springs hold the shoes away from the drum. Brake linings are made of heat-resistant materials and can vary in thickness and shape between shoes. Some systems use servo action to increase the braking force applied. Brake self-adjusters automatically adjust the shoe spacing as the brakes are used. Drums cover the brake mechanisms and provide a surface for shoe contact during braking.
1. The document discusses a study on modeling and analyzing a disc brake system with dual caliper action using SolidWorks finite element analysis software.
2. It aims to compare the displacement, stresses, and strains of an automobile disc brake system with single versus dual caliper design at different vehicle speeds.
3. The dual caliper design activates a second caliper at higher speeds to increase braking efficiency, with the caliper actions controlled by the vehicle's electronic control unit based on speed.
The document summarizes disk brakes, including how they work by squeezing an attached metal disc in a hydraulic caliper to slow a vehicle's wheels. It discusses the history of disk brakes, from animal-drawn vehicles relying on animals to accelerate and decelerate, to the more complex mechanical braking systems as technology advanced. The document also outlines the key advantages of disk brakes like improved efficiency, ability to withstand higher loads, and longer service life compared to drum brakes. Types of disk brakes include fixed and floating caliper designs, with floating calipers used commonly in passenger vehicles and air-actuated sliding calipers often used in commercial vehicles.
This document provides an overview of disc brake systems, including their parts and operation. It discusses the advantages of disc brakes over drum brakes, describing how disc brakes resist different types of fade. It outlines the major components of a disc brake system, such as the caliper, rotor, and pads. It explains the construction and different materials used in brake pads. It also describes the different types of brake calipers, including fixed, floating, and sliding designs.
The document provides information about vehicle braking systems, including:
- The main components and operation of drum and disc brakes.
- Brake design requirements to provide equal braking forces and prevent wheel lockup.
- The six categories that brake system components can be classified into.
- How antilock braking systems work to prevent wheel lockup.
- The federal standards in FMVSS 135 that regulate brake performance requirements through testing procedures.
A disc brake is a type of brake that uses the calipers to squeeze pairs of pads against a disc or rotor to create friction. This action slows the rotation of a shaft, such as a vehicle axle, either to reduce its rotational speed or to hold it stationary. The energy of motion is converted into waste heat which must be dispersed. Disc brake system is widely used on front wheels in mid range two wheeler such as - commuter and sports bikes. The Disc brake system is used on the front wheels of most hatchback cars, entry level sedans and MUVs whereas, it is also widely used on both front and rear wheels of high end cars and SUVs in combination with hydraulic vacuum brake actuating systems. Vikrant Yadav | Pankaj Yadav "Overview of Disc Brake" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-4 | Issue-4 , June 2020, URL: https://www.ijtsrd.com/papers/ijtsrd31530.pdf Paper Url :https://www.ijtsrd.com/engineering/automotive-engineering/31530/overview-of-disc-brake/vikrant-yadav
This document provides an overview of disc brakes, including:
- Disc brakes work by using brake pads in a caliper to create friction against a rotor attached to the wheel, slowing the wheel's rotation.
- Key parts include the master cylinder, brake pedal, caliper, rotor, and brake pads. The caliper houses the pads and presses them against the rotor when braking is applied.
- Disc brakes offer better performance than drum brakes, as they are less affected by weather and do not get clogged. However, they also have higher costs and complexity.
In the existing automobile market which is growing, the competition for better automobile in climbing up enormously. The racing fans involved will surely know the importance of a good brake system not only for safety but also for staying competitive in every race though Brake is the key factor for safety. Braking is a process which converts the kinetic energy of the automobile into mechanical energy for arresting the rotation of the road wheels which must be dissipated in the form of heat.
This document discusses the key components of drum brake systems, including wheel cylinders, brake shoes, brake linings, servo action, brake self-adjusters, and drums. It explains that wheel cylinders contain pistons that apply force to the brake shoes, while return springs hold the shoes away from the drum. Brake linings are made of heat-resistant materials and can vary in thickness and shape between shoes. Some systems use servo action to increase the braking force applied. Brake self-adjusters automatically adjust the shoe spacing as the brakes are used. Drums cover the brake mechanisms and provide a surface for shoe contact during braking.
1. The document discusses a study on modeling and analyzing a disc brake system with dual caliper action using SolidWorks finite element analysis software.
2. It aims to compare the displacement, stresses, and strains of an automobile disc brake system with single versus dual caliper design at different vehicle speeds.
3. The dual caliper design activates a second caliper at higher speeds to increase braking efficiency, with the caliper actions controlled by the vehicle's electronic control unit based on speed.
The document summarizes disk brakes, including how they work by squeezing an attached metal disc in a hydraulic caliper to slow a vehicle's wheels. It discusses the history of disk brakes, from animal-drawn vehicles relying on animals to accelerate and decelerate, to the more complex mechanical braking systems as technology advanced. The document also outlines the key advantages of disk brakes like improved efficiency, ability to withstand higher loads, and longer service life compared to drum brakes. Types of disk brakes include fixed and floating caliper designs, with floating calipers used commonly in passenger vehicles and air-actuated sliding calipers often used in commercial vehicles.
This document provides an overview of disc brake systems, including their parts and operation. It discusses the advantages of disc brakes over drum brakes, describing how disc brakes resist different types of fade. It outlines the major components of a disc brake system, such as the caliper, rotor, and pads. It explains the construction and different materials used in brake pads. It also describes the different types of brake calipers, including fixed, floating, and sliding designs.
The document provides information about vehicle braking systems, including:
- The main components and operation of drum and disc brakes.
- Brake design requirements to provide equal braking forces and prevent wheel lockup.
- The six categories that brake system components can be classified into.
- How antilock braking systems work to prevent wheel lockup.
- The federal standards in FMVSS 135 that regulate brake performance requirements through testing procedures.
This document describes various brake system components and types. It discusses parking brakes, service brakes, hydraulic brakes, drum brakes, disc brakes, and anti-lock brake systems (ABS). Key components include the master cylinder, calipers, rotors, pads, shoes, and various valves and pumps. Hydraulic principles allow force multiplication from the brake pedal. Drum brakes use expanding shoes to brake while disc brakes use calipers and pads to squeeze a rotor. ABS monitors wheel speeds to prevent locking during heavy braking.
In this slide I have shared all details about brake rotors. you will learn a-z all details about brake rotors history and using format, how to buy and so on.
Check out the below link for more details: https://thegaragely.com/best-brake-rotors/
Disc brakes use calipers to squeeze brake pads against a rotor to create friction and slow the rotation of an axle. Bicycle brakes squeeze pads against the wheel, while disc brakes squeeze pads against a disc attached to the wheel or axle. Disc brakes are increasingly used on large vehicles where drum brakes were previously used, as disc brakes provide more predictable braking and fade less when hot. Disc brakes have advantages over drum brakes such as being less prone to issues caused by water trapped between brake components.
The document provides information about disc brake systems, including:
1) Disc brakes use pistons to squeeze brake pads against a rotating disc brake rotor to stop the wheel. Disc brakes have advantages over drum brakes like better resistance to fade.
2) The main parts of a disc brake system are the caliper, brake pads, rotor, and splash shield. Disc brake pads contain a friction material bonded or riveted to a steel backing plate and may have wear indicators.
3) While disc brakes perform better than drum brakes, they also have some disadvantages like producing more brake dust and less self-energizing than drum brakes.
The document discusses wheel bearings, including their types, parts, inspection, and service procedures. It describes the symptoms of defective wheel bearings, such as noise and looseness. The summary explains how to inspect non-drive wheel bearings, including cleaning and packing them with new grease before reinstallation. Special attention is paid to properly adjusting the spindle nut during reinstallation.
Brakes convert kinetic energy into heat to slow or stop moving objects like vehicles. Common brake systems use hydraulic pressure to push brake pads against a rotating drum or disc attached to the wheel. Drum brakes use pads that press against a rotating drum, while disc brakes use pads pressed against a stationary disc by a calliper. Both systems work through hydraulic pressure from the brake pedal to slow rotation. Drum brakes are simpler but larger, while disc brakes provide better stopping power and are less prone to fade. Key components include the brake pads or shoes, drums or discs, wheel cylinders, callipers, and hydraulic lines and fluid which amplify braking force through incompressibility.
This document discusses automotive braking systems. It describes how braking systems work by converting kinetic energy to heat energy through friction between moving and non-moving surfaces at each wheel. The most common types of braking systems are disc and drum brakes. It then explains the basic components and functioning of drum brakes, disc brakes, and hydraulic braking systems. Key components discussed include the master cylinder, brake lines, calipers, wheel cylinders, rotors, and pads. Factors that can affect braking performance and types of brake linings are also outlined.
The document provides information about drum brake components, operation, advantages, and disadvantages. It discusses drum brake shoes, linings, parts such as backing plates, anchors, and adjusters. Drum brakes use self-energizing action and servo effects to apply more stopping power. While prone to issues like fade, drum brakes remain common due to their ability to serve as parking brakes and relative simplicity.
The document provides information about automotive brake systems. It discusses the principles of braking including converting kinetic energy to heat energy through friction. It describes the components of brake systems such as drum brakes, disc brakes, master cylinders, vacuum boosters, ABS systems, and valves. Drum brakes use a wedging action to press brake shoes into the drum while disc brakes use calipers to squeeze brake pads against a rotor. ABS systems use speed sensors and valves controlled by a computer to pulse the brakes near the lock-up point for maximum braking power and control.
The document discusses brake fluid types and specifications. It explains that brake fluid is made from polyglycol and comes in different DOT classifications (DOT 3, DOT 4, DOT 5, DOT 5.1) with varying characteristics like moisture absorption and boiling points. DOT 3 is most commonly used but DOT 4 provides better protection against corrosion. DOT 5 is silicone-based and doesn't absorb water. The document emphasizes the importance of changing brake fluid regularly to prevent issues from low boiling points caused by absorbed moisture.
The document discusses drum brakes, including their components, operation, advantages, and disadvantages. It describes drum brake parts such as the backing plate, shoe anchors, wheel cylinders, brake shoes, and linings. It explains the differences between primary and secondary brake shoes and how drum brakes use self-energizing and servo action to provide stopping power. The document also discusses drum brake fade issues and methods for adjusting drum brakes.
This document discusses disk brakes, including their history, types, advantages, and how they work. Disk brakes use friction pads that squeeze a metal disk attached to the wheel hub to slow rotation. There are two main types - opposed piston brakes, which use pistons on both sides of the disk for even pressure, and floating caliper brakes, which use a piston on the inner side to push the caliper and outer pad against the disk. Disk brakes are more efficient than drum brakes as they dissipate heat better and maintain performance longer under stress.
This document is the general catalogue for SKF, a manufacturer of bearings and related products. It provides an overview of the catalogue, noting it contains standard bearings and accessories. It also describes updates made to the technical section, including new models for determining friction and lubricant viscosity. The catalogue aims to match customer needs and make products available worldwide.
This chapter discusses drum brakes, including their components, operation of non-servo and dual-servo drum brakes, advantages and disadvantages of drum brakes, and automatic brake adjusters. Drum brakes use shoes that press against the inside of a drum to create friction and slow the vehicle. Non-servo brakes apply each shoe individually while dual-servo brakes use one shoe to help apply the other, increasing braking force. Automatic adjusters compensate for brake pad wear to maintain proper clearance between pads and drum.
The document describes various types of hydraulic actuators including cylinders and motors. It discusses the construction and operation of basic hydraulic cylinders, comparing single-acting and double-acting cylinder designs. It also covers cylinder mounting configurations and how force is calculated based on piston area and system pressure.
This document provides information on Scotch-Brite surface conditioning wheels, including convolute and unitized wheels. It includes charts listing wheel types and their applications for deburring, polishing, and finishing of various materials like carbon steel, stainless steel, aluminum and others. It also discusses factors to consider when selecting wheels like material hardness, desired results, and speed capabilities. Convolute wheels generally provide finer finishes while unitized wheels are more aggressive and durable.
This document discusses hydraulic brakes. It begins with an introduction explaining that hydraulic brakes use brake fluid to transfer pressure from the brake pedal to the actual brake mechanism. It then covers the classification, principles, construction, operation, and advantages/disadvantages of hydraulic brakes. The construction section explains the key components including the master cylinder, wheel cylinder, brake shoes, brake drum, brake fluid, and brake lines/hoses. It describes how depressing the brake pedal creates pressure in the master cylinder that is transferred through the brake lines to the wheel cylinders, applying force to the brake pads.
Disc brakes consist of a rotating disc and a stationary caliper with brake pads. When the brake pedal is pressed, fluid pressure from the master cylinder acts on the calipers, squeezing the pads against the disc to slow the wheel. Brake bias bars divide the master cylinder force between the front and rear brakes to provide different braking forces tailored to each vehicle. Race cars especially require brake biasing to optimize braking performance under heavy braking conditions. In conclusion, brake biasing uses a balance bar to adjust the input force to separate front and rear master cylinders for safe and effective braking.
Disk brakes work by squeezing a metal disc attached to the wheel hub using a hydraulic caliper. They provide more efficient braking than drum brakes due to better heat dissipation and a larger friction surface. The document discusses the history and mechanics of disk brakes, comparing different types used in passenger cars and commercial vehicles. Disk brakes offer improved performance under high speeds and loads but require more complex maintenance than drum brakes.
This document summarizes a research paper that models and analyzes a speed dependent dual caliper disc brake system using finite element analysis in SolidWorks. The paper introduces disc brakes and their components. It then discusses modeling a dual caliper disc brake system where a second caliper engages at higher speeds to increase braking power. Finite element models of the brake disc and caliper are created in SolidWorks and simulated. Stress, strain, displacement and other values are analyzed and compared between single and dual caliper systems, finding the dual caliper reduces stopping distance by about 4.63% at 130km/hr. In conclusion, modeling and finite element analysis support that a speed dependent dual caliper disc brake improves braking performance
This document provides an overview of hydraulic brake systems. It describes how hydraulic brake systems use brake fluid under pressure to activate brakes and create friction to stop a vehicle. It outlines the basic components and operation of hydraulic brake systems, including the master cylinder, combination valve, brake lines, wheel/slave cylinders, wheel calipers, brake pads/shoes, and brake drums/rotors. Routine maintenance of hydraulic brake systems involves periodic cleaning, inspection, and adjustment of brake pads/shoes, as well as fluid changes when discolored or containing high moisture. Safety precautions are required any time working on or around brake systems.
The document discusses the optimization of the design of a brake drum for a two-wheeler through reverse engineering using ANSYS software. The authors create CAD models of an existing brake drum and analyze it using finite element analysis to determine stresses and temperature variations under different braking conditions and materials. Their results show that a CE alloy material produces less deformation and lower maximum temperatures than aluminum. They conclude that CE alloys can improve braking performance and are a better candidate material for brake drums compared to aluminum.
This document describes various brake system components and types. It discusses parking brakes, service brakes, hydraulic brakes, drum brakes, disc brakes, and anti-lock brake systems (ABS). Key components include the master cylinder, calipers, rotors, pads, shoes, and various valves and pumps. Hydraulic principles allow force multiplication from the brake pedal. Drum brakes use expanding shoes to brake while disc brakes use calipers and pads to squeeze a rotor. ABS monitors wheel speeds to prevent locking during heavy braking.
In this slide I have shared all details about brake rotors. you will learn a-z all details about brake rotors history and using format, how to buy and so on.
Check out the below link for more details: https://thegaragely.com/best-brake-rotors/
Disc brakes use calipers to squeeze brake pads against a rotor to create friction and slow the rotation of an axle. Bicycle brakes squeeze pads against the wheel, while disc brakes squeeze pads against a disc attached to the wheel or axle. Disc brakes are increasingly used on large vehicles where drum brakes were previously used, as disc brakes provide more predictable braking and fade less when hot. Disc brakes have advantages over drum brakes such as being less prone to issues caused by water trapped between brake components.
The document provides information about disc brake systems, including:
1) Disc brakes use pistons to squeeze brake pads against a rotating disc brake rotor to stop the wheel. Disc brakes have advantages over drum brakes like better resistance to fade.
2) The main parts of a disc brake system are the caliper, brake pads, rotor, and splash shield. Disc brake pads contain a friction material bonded or riveted to a steel backing plate and may have wear indicators.
3) While disc brakes perform better than drum brakes, they also have some disadvantages like producing more brake dust and less self-energizing than drum brakes.
The document discusses wheel bearings, including their types, parts, inspection, and service procedures. It describes the symptoms of defective wheel bearings, such as noise and looseness. The summary explains how to inspect non-drive wheel bearings, including cleaning and packing them with new grease before reinstallation. Special attention is paid to properly adjusting the spindle nut during reinstallation.
Brakes convert kinetic energy into heat to slow or stop moving objects like vehicles. Common brake systems use hydraulic pressure to push brake pads against a rotating drum or disc attached to the wheel. Drum brakes use pads that press against a rotating drum, while disc brakes use pads pressed against a stationary disc by a calliper. Both systems work through hydraulic pressure from the brake pedal to slow rotation. Drum brakes are simpler but larger, while disc brakes provide better stopping power and are less prone to fade. Key components include the brake pads or shoes, drums or discs, wheel cylinders, callipers, and hydraulic lines and fluid which amplify braking force through incompressibility.
This document discusses automotive braking systems. It describes how braking systems work by converting kinetic energy to heat energy through friction between moving and non-moving surfaces at each wheel. The most common types of braking systems are disc and drum brakes. It then explains the basic components and functioning of drum brakes, disc brakes, and hydraulic braking systems. Key components discussed include the master cylinder, brake lines, calipers, wheel cylinders, rotors, and pads. Factors that can affect braking performance and types of brake linings are also outlined.
The document provides information about drum brake components, operation, advantages, and disadvantages. It discusses drum brake shoes, linings, parts such as backing plates, anchors, and adjusters. Drum brakes use self-energizing action and servo effects to apply more stopping power. While prone to issues like fade, drum brakes remain common due to their ability to serve as parking brakes and relative simplicity.
The document provides information about automotive brake systems. It discusses the principles of braking including converting kinetic energy to heat energy through friction. It describes the components of brake systems such as drum brakes, disc brakes, master cylinders, vacuum boosters, ABS systems, and valves. Drum brakes use a wedging action to press brake shoes into the drum while disc brakes use calipers to squeeze brake pads against a rotor. ABS systems use speed sensors and valves controlled by a computer to pulse the brakes near the lock-up point for maximum braking power and control.
The document discusses brake fluid types and specifications. It explains that brake fluid is made from polyglycol and comes in different DOT classifications (DOT 3, DOT 4, DOT 5, DOT 5.1) with varying characteristics like moisture absorption and boiling points. DOT 3 is most commonly used but DOT 4 provides better protection against corrosion. DOT 5 is silicone-based and doesn't absorb water. The document emphasizes the importance of changing brake fluid regularly to prevent issues from low boiling points caused by absorbed moisture.
The document discusses drum brakes, including their components, operation, advantages, and disadvantages. It describes drum brake parts such as the backing plate, shoe anchors, wheel cylinders, brake shoes, and linings. It explains the differences between primary and secondary brake shoes and how drum brakes use self-energizing and servo action to provide stopping power. The document also discusses drum brake fade issues and methods for adjusting drum brakes.
This document discusses disk brakes, including their history, types, advantages, and how they work. Disk brakes use friction pads that squeeze a metal disk attached to the wheel hub to slow rotation. There are two main types - opposed piston brakes, which use pistons on both sides of the disk for even pressure, and floating caliper brakes, which use a piston on the inner side to push the caliper and outer pad against the disk. Disk brakes are more efficient than drum brakes as they dissipate heat better and maintain performance longer under stress.
This document is the general catalogue for SKF, a manufacturer of bearings and related products. It provides an overview of the catalogue, noting it contains standard bearings and accessories. It also describes updates made to the technical section, including new models for determining friction and lubricant viscosity. The catalogue aims to match customer needs and make products available worldwide.
This chapter discusses drum brakes, including their components, operation of non-servo and dual-servo drum brakes, advantages and disadvantages of drum brakes, and automatic brake adjusters. Drum brakes use shoes that press against the inside of a drum to create friction and slow the vehicle. Non-servo brakes apply each shoe individually while dual-servo brakes use one shoe to help apply the other, increasing braking force. Automatic adjusters compensate for brake pad wear to maintain proper clearance between pads and drum.
The document describes various types of hydraulic actuators including cylinders and motors. It discusses the construction and operation of basic hydraulic cylinders, comparing single-acting and double-acting cylinder designs. It also covers cylinder mounting configurations and how force is calculated based on piston area and system pressure.
This document provides information on Scotch-Brite surface conditioning wheels, including convolute and unitized wheels. It includes charts listing wheel types and their applications for deburring, polishing, and finishing of various materials like carbon steel, stainless steel, aluminum and others. It also discusses factors to consider when selecting wheels like material hardness, desired results, and speed capabilities. Convolute wheels generally provide finer finishes while unitized wheels are more aggressive and durable.
This document discusses hydraulic brakes. It begins with an introduction explaining that hydraulic brakes use brake fluid to transfer pressure from the brake pedal to the actual brake mechanism. It then covers the classification, principles, construction, operation, and advantages/disadvantages of hydraulic brakes. The construction section explains the key components including the master cylinder, wheel cylinder, brake shoes, brake drum, brake fluid, and brake lines/hoses. It describes how depressing the brake pedal creates pressure in the master cylinder that is transferred through the brake lines to the wheel cylinders, applying force to the brake pads.
Disc brakes consist of a rotating disc and a stationary caliper with brake pads. When the brake pedal is pressed, fluid pressure from the master cylinder acts on the calipers, squeezing the pads against the disc to slow the wheel. Brake bias bars divide the master cylinder force between the front and rear brakes to provide different braking forces tailored to each vehicle. Race cars especially require brake biasing to optimize braking performance under heavy braking conditions. In conclusion, brake biasing uses a balance bar to adjust the input force to separate front and rear master cylinders for safe and effective braking.
Disk brakes work by squeezing a metal disc attached to the wheel hub using a hydraulic caliper. They provide more efficient braking than drum brakes due to better heat dissipation and a larger friction surface. The document discusses the history and mechanics of disk brakes, comparing different types used in passenger cars and commercial vehicles. Disk brakes offer improved performance under high speeds and loads but require more complex maintenance than drum brakes.
This document summarizes a research paper that models and analyzes a speed dependent dual caliper disc brake system using finite element analysis in SolidWorks. The paper introduces disc brakes and their components. It then discusses modeling a dual caliper disc brake system where a second caliper engages at higher speeds to increase braking power. Finite element models of the brake disc and caliper are created in SolidWorks and simulated. Stress, strain, displacement and other values are analyzed and compared between single and dual caliper systems, finding the dual caliper reduces stopping distance by about 4.63% at 130km/hr. In conclusion, modeling and finite element analysis support that a speed dependent dual caliper disc brake improves braking performance
This document provides an overview of hydraulic brake systems. It describes how hydraulic brake systems use brake fluid under pressure to activate brakes and create friction to stop a vehicle. It outlines the basic components and operation of hydraulic brake systems, including the master cylinder, combination valve, brake lines, wheel/slave cylinders, wheel calipers, brake pads/shoes, and brake drums/rotors. Routine maintenance of hydraulic brake systems involves periodic cleaning, inspection, and adjustment of brake pads/shoes, as well as fluid changes when discolored or containing high moisture. Safety precautions are required any time working on or around brake systems.
The document discusses the optimization of the design of a brake drum for a two-wheeler through reverse engineering using ANSYS software. The authors create CAD models of an existing brake drum and analyze it using finite element analysis to determine stresses and temperature variations under different braking conditions and materials. Their results show that a CE alloy material produces less deformation and lower maximum temperatures than aluminum. They conclude that CE alloys can improve braking performance and are a better candidate material for brake drums compared to aluminum.
Design & Analysis of a Disc Brake using Feaijceronline
International Journal of Computational Engineering Research (IJCER) is dedicated to protecting personal information and will make every reasonable effort to handle collected information appropriately. All information collected, as well as related requests, will be handled as carefully and efficiently as possible in accordance with IJCER standards for integrity and objectivity.
DESIGN MODIFICATION OF DISC BRAKE AND PERFORMANCE ANALYSIS OF IT BY VARYING T...ijsrd.com
Automobile braking system is one of the most important mechanical devices among the others. The disc brake is a device that slows or stops the rotation of a wheel by converting the friction to heat. But if the brakes get too hot, they will cease to work as they cannot dissipate enough heat. This condition of failure is known as brake fade. Disc brakes are exposed to large thermal stresses during routine braking and extraordinary thermal stresses during hard braking. Ventilation applications on disc brake can significantly improve the brake system performance by reducing the heating of the discs. In this study, the thermal behavior as well as the performance of ventilated brake discs using different pattern of holes will be investigated at continuous brake conditions with finite element analysis and the results will be compared with a solid disc.
The document provides information about braking systems in automobiles. It discusses the components and functioning of drum brakes and disc brakes. It also describes the hydraulic brake system used in most passenger vehicles and the introduction of anti-lock braking systems (ABS) in the 1980s. ABS uses sensors and valves to prevent wheel lockup during hard braking, maintaining steering control. Causes of brake failure include issues that reduce friction like grease or worn components, and remedies involve replacing or adjusting the faulty parts.
CFD Analysis Of Straight Ventilated Disc BrakeIJERA Editor
Brakes are the key pieces of a vehicle that plays an active role in safety and performance of the system. The
study of aerodynamic cooling of a disc brake in real working condition of vehicle is important in present
situations. Brake discs get very hot quickly, so it should be dissipated properly through different modes of heat
transfer. Contributions of these heat transfer modes are different in different type of problems. The cooling
transfer rates are different in vane surface and frictional surface of a disc brake. Also the temperature varies in
each small interval of braking time. So a transient problem simulation is important to study the cooling of a disc
brake when a vehicle decelerates from a particular speed. ANSYS CFX tool is used for the simulation of this
transient problem.
This document summarizes an investigation into how brake disk design affects cooling. Three different disk designs were tested: a standard vented disk, a new standard disk, a grooved disk, and a cross-drilled disk. Thermal imaging was used to monitor temperatures during braking tests. While additional design features were expected to improve cooling, results showed this was not always the case. Testing found the grooved disk cooled slower than the standard disk in some cases. Further analysis is needed to fully understand how disk design impacts braking temperature.
Society of Automobile Engineering,Southern section India. As a part of virtual baja 2017. Awarded as best. Detailed info regarding braking of a 4*4 offroad vehicle(ATV)
Traditional manufacturing processes vs Advanced manufacturing processesSisubalan Selvan
The document discusses the manufacturing processes for a disc brake part. It begins by introducing the group members and their task to identify the material and processes for an engineered part they selected, which was a disc brake. It then provides details on the specific processes and material used to produce a disc brake part, including:
1) Disc brakes are typically made of gray cast iron due to its properties like thermal stability and cost effectiveness.
2) The production process for a ceramic composite disc brake involves steps like pouring carbon fiber into a mold and pressing the ceramic material into a die.
3) Essential properties like dimensional accuracy, surface finish, and weight distribution are considered to ensure proper performance.
4) Disc
Abstract— A brake is a mechanical gadget which hinders movement. Its inverse part is a grasp. Vortex current brakes utilize attractive fields to change over motor vitality into electric current in the brake plate, blade, or rail, which is changed over into warmth. Brakes are by and large connected to turning axles or wheels, however may likewise take different structures, for example, the surface of a moving liquid (folds sent into water or air). Erosion brakes on autos store braking heat in the drum brake or circle brake while braking then direct it to the air step by step. When voyaging downhill a few vehicles can utilize their motors to brake.When the brake pedal of a present day vehicle with pressure driven brakes is pushed, at last a cylinder pushes the brake cushion against the brake plate which backs the wheel off. On the brake drum it is comparable as the chamber pushes the brake shoes against the drum which additionally backs the wheel off.
Keywords— Brake, Wedge shaped, Wheel.
JDVP Day 32 & 33 Lesson 28 Automotive Brake System and Its Components.pptxMarcel Imperial
The document discusses the automotive brake system and its components. It begins with an introduction to the training session's objectives which are to discuss the function, classification, components, principles and common troubles of brake systems. It then defines what a brake system is and its purpose to stop a vehicle. It classifies brake systems as mechanical, hydraulic, electric, vacuum or air brakes. It identifies common components such as the brake pedal, master cylinder, fluid lines, wheel cylinder, calipers, brake pads/shoes, rotor disc, and drum. It explains the working principle of hydraulic brakes and factors that can influence braking like road conditions. Finally, it lists some common problems and their possible causes and remedies.
The document discusses vehicle braking systems. It explains that braking works by converting kinetic energy to heat energy through friction between a moving brake component and a stationary one. The most common braking systems are disc brakes and drum brakes. It then provides details on components of braking systems like the master cylinder, brake lines, and brake assemblies.
The document provides information about different types of braking systems used in vehicles. It discusses drum brakes and disc brakes, describing their main components and how they work. It also covers different classification criteria for brakes, including purpose, location, construction, and actuation method. Under actuation method, it briefly explains mechanical, hydraulic, electric, vacuum, and air brakes. For each main type, it provides one to two sentences on their basic working principle.
This document contains a summer training report submitted by Ravinder in partial fulfillment of a Bachelor of Technology degree in Mechanical Engineering. The report details Ravinder's 42-day summer internship at Lakshmi Precision Screws Ltd. in Rohtak, where he trained under the guidance of manager Vijay Kumar Jain. The report includes sections on the company, types of brakes, disc brakes, drum brakes, and provides technical details and images related to the Mahindra Bolero vehicle and its brake systems.
The document discusses various types of braking systems used in automobiles, including mechanical brakes, hydraulic brakes, power brakes, drum brakes, and disc brakes. It provides details on the components and working of hydraulic braking systems, drum brakes, and disc brakes through diagrams. The document also discusses regenerative braking, anti-lock braking systems, and describes power brakes and notes the types used including air brakes, air-hydraulic brakes, vacuum brakes, and electric brakes.
Brakes use friction to convert the kinetic energy of a moving vehicle into heat energy via brake pads or shoes pressing against a rotating brake drum or disc. Hydraulic brakes utilize incompressible brake fluid and Pascal's law to transmit pressure evenly to brake components attached to each wheel, allowing for equal braking force. Disc brakes use calipers to squeeze brake pads against a rotor attached to the wheel, while drum brakes use shoes that expand outward to press against a rotating drum enclosed within the brake assembly.
The document describes the design of a six-cylinder internal combustion engine. It includes summaries of the design and function of key engine components like the piston, engine block, crankshaft, valves cover, rocker arm, oil pan, intake manifold, exhaust manifold, engine valves, cylinder head, camshaft, air turbo, and air filter. CAD drawings were created using Solidworks to illustrate the engine structure and connection of parts. Calculations were performed to determine appropriate materials, forces, stresses, and ensure equilibrium during operation. An animation was created to simulate the designed engine.
The document provides information about BAJA SAE India, an intercollegiate engineering design competition. It discusses that the objective is to simulate real-world engineering projects and challenges. Teams must design, build, test, and compete with a vehicle within the competition rules. There are two vehicle categories: internal combustion and electric vehicles. The competition consists of three phases - preliminary, virtual, and physical dynamic events. It then provides overviews of the key vehicle systems and departments involved in BAJA vehicles, including frames and ergonomics, suspension and steering, powertrain, brakes, and statics. It discusses the components, design considerations, and analysis methods for each department.
Aditya Yadav is a mechanical engineer with a Master's degree from the University of South Florida specializing in product design and manufacturing. He has experience in design, validation, CAD, CAE, prototyping, and manufacturing. His technical skills include SolidWorks, Creo, Catia, Ansys, and MATLAB. He has worked on several student racing projects involving the design and fabrication of formula-style cars, all-terrain vehicles, go-karts utilizing CAD software and FEA analysis. He is seeking new opportunities in mechanical engineering.
Aditya Yadav is a mechanical engineer seeking a position involving design, validation, or manufacturing. He has a master's degree and over a decade of experience in mechanical engineering. This includes participating in and leading formula racing, Baja, and go-kart teams where he helped design, manufacture, and test race vehicles. He also has work experience in product design, CAD training, and facility maintenance.
The document is a scanned receipt from a grocery store purchase on June 15th, 2022 totaling $58.37. It lists items bought including ground beef, chicken breasts, tortillas, cheese, and produce such as tomatoes, lettuce, and onions. The receipt shows the item prices, taxes, and total amount due.
Government of India Modular Employee skill Aditya Yadav
The document is a scanned receipt from a grocery store purchase on June 15th, 2022 totaling $58.37. It lists items bought including ground beef, chicken breasts, tortillas, cheese, and produce such as tomatoes, lettuce, and onions. The receipt shows the item prices, taxes, and total amount due.
The document is a scanned receipt from a grocery store purchase on June 15th, 2022 totaling $58.37. It lists items bought including ground beef, chicken breasts, tortillas, cheese, and produce such as tomatoes, lettuce, and onions. The receipt shows the item prices, taxes, and total amount due.
The document is a scanned receipt from a grocery store listing items purchased including milk, eggs, bread, and cheese. The total for the grocery purchase came to $23.45 after tax. The receipt provides a record of items bought and payment made for a routine trip to the grocery store.
The document is a scanned receipt from a grocery store purchase on June 15th, 2022 totaling $58.37. It lists items bought including ground beef, chicken breasts, tortillas, cheese, and produce such as tomatoes, lettuce, and onions. The receipt shows the item prices, taxes, and total amount due.
The document is a scanned receipt from a grocery store purchase on June 15th, 2022 totaling $58.37. It lists items bought including ground beef, chicken breasts, tortillas, cheese, and produce such as tomatoes, lettuce, and onions. The receipt shows the item prices, taxes, and total amount due.
The document is a scanned receipt from a grocery store purchase on January 15th, 2023 for $58.46. It lists the items bought which include milk, eggs, bread, cereal, orange juice, and bananas. The payment was made with a credit card ending in 4321.
The document is a scanned receipt from a grocery store purchase on January 15th, 2023 for $58.46. It lists the items bought which include milk, eggs, bread, bananas, and ground beef. The payment was made with a credit card ending in 4321.
The document outlines the key details of a home sale including the purchase price of $450,000, a closing date of June 15th, 2022, and contingencies requiring the home to pass inspection and the buyer to obtain financing by May 15th.
The document is a scanned receipt from a restaurant showing a total of $58.95 was spent. It lists items purchased including drinks, appetizers, entrees and dessert. The receipt details the date, time, payment method and includes a thank you message from the restaurant.
The document is a scanned receipt from a grocery store purchase on June 15th, 2022 totaling $58.37. It lists items bought including ground beef, chicken breasts, tortillas, cheese, and produce such as tomatoes, lettuce, and onions. The receipt shows the item prices, taxes, and total amount due.
The document is a scanned receipt from a grocery store purchase on January 15th, 2023 for $58.46. It lists the items bought which include milk, eggs, bread, cereal, orange juice, bananas, and ground beef. The payment was made with a credit card ending in 4321.
The document is a scanned receipt from a grocery store purchase on June 15th, 2022 totaling $58.37. It lists items bought including ground beef, chicken breasts, tortillas, cheese, and produce such as tomatoes, lettuce, and onions. The receipt shows the item prices, taxes, and total amount due.
The document is a scanned receipt from a grocery store purchase on June 15th, 2022 totaling $58.37. It lists items bought including ground beef, chicken breasts, tortillas, cheese, and produce such as tomatoes, lettuce, and onions. The receipt shows the item prices, taxes, and total amount due.
This certificate of participation recognizes Aditya Sunil Yadav of the University of South Florida for participating in the Formula SAE Michigan competition held from May 8-11, 2019 in Brooklyn, Michigan. The certificate acknowledges Yadav's involvement in the competition organized by the Society of Automotive Engineers.
This certificate verifies that Aditya Yadav completed a course on Creo Parametric from March 2014 to May 2018 at CADD Centre Training Services in Pune, India. The course covered topics including GD&T basics, tolerance dimensioning, introduction to the ASME Y14.5M-1994 standard, creating sketches, parts, assemblies, drawings, and sheet metal designs in Creo Parametric. Aditya was certified in GD&T and the use of Creo Parametric for mechanical design.
The document summarizes the finite element analysis of a Formula SAE racing car chassis. It describes the design goals of high ground clearance, light weight, strength, and driver safety. Steel tubing was selected for the chassis material. A torsional analysis found the chassis has a torsional rigidity of 2561.26 N.m/Degree. Additional analyses included front and rear impact simulations and a modal analysis to ensure the chassis' natural frequencies do not match the engine's operating frequencies. Future work will focus on a monocoque carbon fiber chassis design.
This document is a design report for a go-kart called Team Nexus Racing created by undergraduate engineering students. It details the design of the kart which aims to be eco-friendly with high fuel economy, driver comfort while meeting performance needs. The report describes the individual components of the kart like the chassis, steering system, brakes that were modeled in CAD software and analyzed in ANSYS. It provides technical specifications, diagrams of the kart design, and summaries the analyses conducted to optimize the design.
Electric vehicle and photovoltaic advanced roles in enhancing the financial p...IJECEIAES
Climate change's impact on the planet forced the United Nations and governments to promote green energies and electric transportation. The deployments of photovoltaic (PV) and electric vehicle (EV) systems gained stronger momentum due to their numerous advantages over fossil fuel types. The advantages go beyond sustainability to reach financial support and stability. The work in this paper introduces the hybrid system between PV and EV to support industrial and commercial plants. This paper covers the theoretical framework of the proposed hybrid system including the required equation to complete the cost analysis when PV and EV are present. In addition, the proposed design diagram which sets the priorities and requirements of the system is presented. The proposed approach allows setup to advance their power stability, especially during power outages. The presented information supports researchers and plant owners to complete the necessary analysis while promoting the deployment of clean energy. The result of a case study that represents a dairy milk farmer supports the theoretical works and highlights its advanced benefits to existing plants. The short return on investment of the proposed approach supports the paper's novelty approach for the sustainable electrical system. In addition, the proposed system allows for an isolated power setup without the need for a transmission line which enhances the safety of the electrical network
A review on techniques and modelling methodologies used for checking electrom...nooriasukmaningtyas
The proper function of the integrated circuit (IC) in an inhibiting electromagnetic environment has always been a serious concern throughout the decades of revolution in the world of electronics, from disjunct devices to today’s integrated circuit technology, where billions of transistors are combined on a single chip. The automotive industry and smart vehicles in particular, are confronting design issues such as being prone to electromagnetic interference (EMI). Electronic control devices calculate incorrect outputs because of EMI and sensors give misleading values which can prove fatal in case of automotives. In this paper, the authors have non exhaustively tried to review research work concerned with the investigation of EMI in ICs and prediction of this EMI using various modelling methodologies and measurement setups.
International Conference on NLP, Artificial Intelligence, Machine Learning an...gerogepatton
International Conference on NLP, Artificial Intelligence, Machine Learning and Applications (NLAIM 2024) offers a premier global platform for exchanging insights and findings in the theory, methodology, and applications of NLP, Artificial Intelligence, Machine Learning, and their applications. The conference seeks substantial contributions across all key domains of NLP, Artificial Intelligence, Machine Learning, and their practical applications, aiming to foster both theoretical advancements and real-world implementations. With a focus on facilitating collaboration between researchers and practitioners from academia and industry, the conference serves as a nexus for sharing the latest developments in the field.
A SYSTEMATIC RISK ASSESSMENT APPROACH FOR SECURING THE SMART IRRIGATION SYSTEMSIJNSA Journal
The smart irrigation system represents an innovative approach to optimize water usage in agricultural and landscaping practices. The integration of cutting-edge technologies, including sensors, actuators, and data analysis, empowers this system to provide accurate monitoring and control of irrigation processes by leveraging real-time environmental conditions. The main objective of a smart irrigation system is to optimize water efficiency, minimize expenses, and foster the adoption of sustainable water management methods. This paper conducts a systematic risk assessment by exploring the key components/assets and their functionalities in the smart irrigation system. The crucial role of sensors in gathering data on soil moisture, weather patterns, and plant well-being is emphasized in this system. These sensors enable intelligent decision-making in irrigation scheduling and water distribution, leading to enhanced water efficiency and sustainable water management practices. Actuators enable automated control of irrigation devices, ensuring precise and targeted water delivery to plants. Additionally, the paper addresses the potential threat and vulnerabilities associated with smart irrigation systems. It discusses limitations of the system, such as power constraints and computational capabilities, and calculates the potential security risks. The paper suggests possible risk treatment methods for effective secure system operation. In conclusion, the paper emphasizes the significant benefits of implementing smart irrigation systems, including improved water conservation, increased crop yield, and reduced environmental impact. Additionally, based on the security analysis conducted, the paper recommends the implementation of countermeasures and security approaches to address vulnerabilities and ensure the integrity and reliability of the system. By incorporating these measures, smart irrigation technology can revolutionize water management practices in agriculture, promoting sustainability, resource efficiency, and safeguarding against potential security threats.
Low power architecture of logic gates using adiabatic techniquesnooriasukmaningtyas
The growing significance of portable systems to limit power consumption in ultra-large-scale-integration chips of very high density, has recently led to rapid and inventive progresses in low-power design. The most effective technique is adiabatic logic circuit design in energy-efficient hardware. This paper presents two adiabatic approaches for the design of low power circuits, modified positive feedback adiabatic logic (modified PFAL) and the other is direct current diode based positive feedback adiabatic logic (DC-DB PFAL). Logic gates are the preliminary components in any digital circuit design. By improving the performance of basic gates, one can improvise the whole system performance. In this paper proposed circuit design of the low power architecture of OR/NOR, AND/NAND, and XOR/XNOR gates are presented using the said approaches and their results are analyzed for powerdissipation, delay, power-delay-product and rise time and compared with the other adiabatic techniques along with the conventional complementary metal oxide semiconductor (CMOS) designs reported in the literature. It has been found that the designs with DC-DB PFAL technique outperform with the percentage improvement of 65% for NOR gate and 7% for NAND gate and 34% for XNOR gate over the modified PFAL techniques at 10 MHz respectively.
ACEP Magazine edition 4th launched on 05.06.2024Rahul
This document provides information about the third edition of the magazine "Sthapatya" published by the Association of Civil Engineers (Practicing) Aurangabad. It includes messages from current and past presidents of ACEP, memories and photos from past ACEP events, information on life time achievement awards given by ACEP, and a technical article on concrete maintenance, repairs and strengthening. The document highlights activities of ACEP and provides a technical educational article for members.
Advanced control scheme of doubly fed induction generator for wind turbine us...IJECEIAES
This paper describes a speed control device for generating electrical energy on an electricity network based on the doubly fed induction generator (DFIG) used for wind power conversion systems. At first, a double-fed induction generator model was constructed. A control law is formulated to govern the flow of energy between the stator of a DFIG and the energy network using three types of controllers: proportional integral (PI), sliding mode controller (SMC) and second order sliding mode controller (SOSMC). Their different results in terms of power reference tracking, reaction to unexpected speed fluctuations, sensitivity to perturbations, and resilience against machine parameter alterations are compared. MATLAB/Simulink was used to conduct the simulations for the preceding study. Multiple simulations have shown very satisfying results, and the investigations demonstrate the efficacy and power-enhancing capabilities of the suggested control system.
Using recycled concrete aggregates (RCA) for pavements is crucial to achieving sustainability. Implementing RCA for new pavement can minimize carbon footprint, conserve natural resources, reduce harmful emissions, and lower life cycle costs. Compared to natural aggregate (NA), RCA pavement has fewer comprehensive studies and sustainability assessments.
We have compiled the most important slides from each speaker's presentation. This year’s compilation, available for free, captures the key insights and contributions shared during the DfMAy 2024 conference.
1. Project Guide: Dr. Guldiken
Project by:
1. Aditya Yadav (CFD and
Design)
2. Sudesh Jadhav (CFD)
3. Nishant Sule (Design)
4. Krishna Aravinthan
(Design)
Brake System Design and Brake Fluid Flow
Comparison
Group ID-10
2. HYDRAULIC BRAKING SYSTEM
2
Table of Contents
List of Figures............................................................................................................................3
Introduction .............................................................................................................................. 4
Abstract......................................................................................................................................4
Background ...............................................................................................................................5
Classification.............................................................................................................................9
Design Procedure.....................................................................................................................13
Stress Calculations and Analysis.............................................................................................15
Conclusion and Reference .....................................................................................................25
3. HYDRAULIC BRAKING SYSTEM
3
List of Figures
Figure 1: Example of the Lever Brake.................................................................................. 6
Figure 2: Example of a Disk & Drum Brake.........................................................................7
Figure 3: Brake Rotors..........................................................................................................8
Figure 4: Brake Pads ............................................................................................................9
Figure 5: Foot Actuated Brake.............................................................................................10
Figure 6: Hand Actuated Brake...........................................................................................10
Figure 7: Air Brake...............................................................................................................10
Figure 8:Electric Brake ……….............................................................................................11
Figure 9:Hydraulic Brake.....................................................................................................11
Figure 10: Mechanical Brake........................................................................................... ...12
Figure 11:Vaccume Brake....................................................................................................12
Figure 12: Principle of Braking ..........................................................................................13
Figure 13: Tandem Master Cylinder...................................................................................15
Figure 14:Pedal Orientation...............................................................................................16
Figure 15: Pedal Design & Mounting.................................................................................16
Figure 16: Stresses in Disc..................................................................................................17
Figure 17: Deformation in Disc..........................................................................................17
Figure 18:Stresses in Pedal ................................................................................................17
Figure 19:Deformation in Pedal.........................................................................................17
Figure 20: Notation of Various Parameters....................................................................... 18
Figure 21:Simplified stopping Period Graph .....................................................................19
Figure 22: 2D Space Model………………….......................................................................22
Figure 23:Mesh ..................................................................................................................22
Figure 24:CFD of OEM Brake System...............................................................................24
Figure 25: CFD of Customize Braking System..................................................................25
4. HYDRAULIC BRAKING SYSTEM
4
Introduction
In this Project we are comparing Original Equipment Manufacturer (OEM) brake design with
our custom design. The main objective of this project is to calculate the pressure at the caliper
end and compare it with our model by using Computational Fluid Dynamics (CFD). There
are two types of braking systems such as Disc Brakes and Drum Brakes out of which we have
done analysis on Disc Brake which uses hydraulic fluid to stop the vehicle. There are three
types of disc brakes such as rotating axis, symmetrical disc and stationary pads. In hydraulic
braking system the fluid which is in master cylinder is used to put pressure at the caliper end
to stop the vehicle by pressing the pedal. The disc brakes have immediate stopping response
as compare to drum brakes.
There are various components in the disc brake that we have designed and while designing
there were several factors that we have consider. First, the braking system should bring the
vehicle to quick and safe stop and all four vehicles should lock in static condition. The design
of the braking system is such that for every wheel we have provided independent hydraulic
circuits in our design which makes this design more efficient because even if there is a
leakage at any wheel the barking power will remain the same.
We have used the Pascal’s law in our project to calculate the pressure which says that
“Pressure exerted anywhere in a mass of confined liquid is transmitted undiminished in
all directions throughout the liquid”.
There are several assumptions that we have considered in terms of brake force applied,
vehicle gross weight and coefficient of friction. Also, there are other measurements such as
length, diameter and pedal ratio which we have assumed to make our own design. In CFD we
have defined the boundary conditions to analyze the fluid flow through master cylinder brake
liner. In our final CFD results we found out pressure values at caliper end and we compared it
with OEM results. While comparing CFD results the value of pressure we got was lower than
OEM brake system.
5. HYDRAULIC BRAKING SYSTEM
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ABSTRACT
The current tendencies in automotive industry need intensive investigation in
problems of interaction of active safety systems with brake system equipment’s. The same
time, the chances to diminish the power take-off of single parts,
disc brake systems. Disc brakes are a flat, disc-shaped metal rotor that rotates with the rim.
At the point when the brakes are connected, a caliper crushes the brake pads against the disk
should as you would stop a turning circle by squeezing it between your fingers, abating the
wheel. The disk brake utilized as a part of the vehicle is separated into two parts a rotating
axis symmetrical disk, and the stationary pads. The hydraulic disk brake is a course of action
of braking component which utilizes brake fluids, normally containing ethylene glycol, to
transfer pressure from the controlling unit, which is usually near the operator of the vehicle,
to the actual brake instrument, which is generally at or close to the wheel of the vehicle.
The frictional heat, which is created on the interface of the disk and pads, can cause high
temperature during the braking. Therefore, the vehicles for the most part use disc brakes
on the front Drum brakes on the rear wheels. The disk Brakes have good stopping and
are usually more secure and more productive than drum brakes. The four-wheel circle brakes
are more well known, swapping drums on everything except the most basic vehicles. Many
two wheel automobiles configuration utilizes a drum brake for the rear wheel.
Brake that came into its peak existence in the 60's to proficiently deliver
adequate braking for automobiles has ended in an industry where brakes run from sufficient
to downright sensation. One of the initial steps taken to enhance braking came in the mid 70's
when manufacturers, on a widespread scale, switched from drum to disc brake. Therefor it
has set a mark that the braking begins with the front wheels and only those were modernized
to disk during most of the period. Hence then, many manufacturers have received four-wheel
circle brakes on their top of the line and execution models too as their low-line economy
autos. Very often, the manufacturers go back to the drum brakes framework for the behind
wheels of auto so as to reduce the manufacturing and buying cost.
6. HYDRAULIC BRAKING SYSTEM
6
Background
The principle documented instance of brakes being used was in old Rome. These brakes were
made from a lever that when pulled, squeezed a wooden square onto the outside of a metal
lined wheel. The essential power for braking with this gadget was friction. This technique
was successful because of the low velocities at which the cart moved; in any case, it was a
lacking type of abating runaway carts. This strategy for braking was utilized for quite a long
time with little design change.
Figure 1: Example of the Lever Brake
At the point when the Michelin siblings designed rubber-covered wheel wooden blocks were
substituted with drum brakes. Louis
Renault developed drum brakes in 1902.
Rather than applying a square to the
outside of the wheel, drum brakes were
mounted within the wheel center points.
This limited dirt blockage and diminish
the loss in braking friction. Drum brakes
are still being used in autos as handbrakes
because of the substantial large measure
of power required to conquer the brake
constrain while at equilibrium. Figure 1: Lever Brake
With the presentation of the mechanical production system, autos wound up noticeably
heavier and quicker, which made a requirement for a more capable braking mechanism.
Malcolm Loughead made a four-wheeled hydraulic Braking mechanism. The hydraulic
system utilizes lines loaded with pressure driven liquid as opposed to cable braking
mechanisms. The fundamental favorable position to hydraulic Braking mechanisms is that
they can apply a more noteworthy braking power than cable system. cable brakes weakness
quicker than hydraulic brakes because of the steady pressure that the cable is under. hydraulic
brakes enabled the driver to apply less power onto the brake pedal while yet stopping in a
7. HYDRAULIC BRAKING SYSTEM
7
similar short distance. All through braking history the issue of overheating has been a steady
issue. Heating happens when the brake cushions interact with the braking surface. The key
factor in scattering heat is having a bigger surface area for the brake to cool off.
Disk brakes have a vast surface region exposed to the air, which causes it to stay cooler.
There are holes and grooves cut into the rotor of the Braking mechanism to enable water and
dirt to be moved off the braking surface and limit interference, which causes loss of braking
power.
Figure 2: Disc and Drum Brakes
Disk brakes did not begin getting to be mainstream in vehicles until the point that the 1950's
even though they were invented around 1902. Disk brakes are appended inside the rim of the
vehicle and turn as one with the wheel. At the point when constrain from the driver's foot is
connected to the brake pedal the brake liquid goes through hydraulic cables and progresses
toward becoming enhanced by the power Braking mechanism appended to the engine; this
thusly drives the brake liquid against the caliper which utilizes frictional power to slow the
vehicle.
Fast vehicles require brake pads and calipers to be made of various materials to reproduce the
same braking system needed to stop slower less advanced vehicles, because of the more
prominent measure of idleness that is attempting to be stopped.
8. HYDRAULIC BRAKING SYSTEM
8
There are five primary materials utilized as a part of brake rotors. The five materials most
normally found in brake rotors are solid metal, steel, layered steel, aluminum, and high
carbon irons. Production cars utilize cast iron brakes because of the measure of mishandle
that they can deal with without splitting or failing. Steel brakes have a lighter weight and heat
limit, yet lack durability in repeated employments. Heat can scatter quicker with layered steel
brakes on the grounds that adding layers to basic steel brakes takes into account a more
grounded material that can withstand a more thorough workload. Aluminum brakes have the
most minimal weight of all vehicle rotors. Heat is scattered faster, however the aggregate
with respect to heat absorption is lower than in steel brakes; this is the reason aluminum is
most generally utilized as a part of bikes and other little vehicles. The last sort for brake
material that is utilized is high carbon iron. High measures of carbon take into consideration
expanded heat diffusion, which makes this kind of brake most normally utilized as a part of
high performance vehicles.
Figure 3: Brake Rotors
Brake pads have been made with various materials during the time contingent upon the
utilization. Asbestos was the most mainstream material because of its capacity to absorb and
emit heat. After logical investigations, asbestos has been observed to be an exceedingly
dangerous material and has been prohibited from use in vehicles in the United States. With
asbestos unlawful to utilize, brake producers were compelled to make more secure brakes
from a material that won't hurt the overall population. Organic brakes are produced using
materials that can withstand heat, for instance; glass and rubber are blended with heat
resilient resin to deliver more secure brakes. The upsides of utilizing natural brake cushions
are that they are typically calmer and are simpler to arrange. All things considered, natural
Turner Motorsport
9. HYDRAULIC BRAKING SYSTEM
9
brakes are not normally utilized since they wear effectively, and clean particles gather
between the cushion and wheel, which diminishes the braking surface.
Figure 4: Brake Pads
With a lighter weight to back off, bikes utilize natural and ceramic brake pads. Ceramic brake
pads are the best kind of brake pads however are the most expensive. The most widely
recognized sort of brake pads is made with a blend of a few sorts of metals. These metallic
brakes are sturdy while yet being cost proficient. The negative elements for utilizing metallic
brakes are that they work best when warm and it might take more time to slow at first when
driving in cool climate. With inventions in material science, brakes will keep on improving to
coordinate the advances in auto innovation.
Amazon.com
10. HYDRAULIC BRAKING SYSTEM
10
Classification of Brakes
1. Mode of Actuation
(also, called the main brake) (also called parking brake)
Operated by foot Operated by hand
2. Modes of Power
1. Air Brakes
Air is the abundant in nature where hydraulic fluid is limited. Air brakes are used inn
abundance in trains, trailers and buses and they do not require
hydraulic fluid as other automobiles, which can be exhausted
when there is a leakage. Safety is also concerned where larger
automobiles like trains busses and trailers carry large amount of
cargo and passengers where air brakes are safer medium in
utmost environments unlike fluids. A high-speed automobile
can turn dangerous when the fluid braking system incurs a leak.
The triple value system is used in airbrakes and this system fills a supply tank and uses air
pressure to release the brakes. The Triple value system is in operation until the air is exerted
out completely from the system. As the medium is air it is less expensive.
Figure 7: Air Brake
Figure 6: Hand BrakeFigure 5: Hand Brake
YouTube Auto | HowStuffWorks
Wikipedia
11. HYDRAULIC BRAKING SYSTEM
11
2. Electric Brakes
In electromagnetic brakes electric motor is the essential part which uses electricity as a mode
to generate heat which stops the vehicle. Instead of motor some vehicles use retarder which
generates braking force by internal short-circuit. In this braking system magnetic force act as
a braking force which is also called as mechanical braking system. Eddy current brakes also
uses same principle instead of using drag force it uses electromagnetic force between magnet
and an object which is a conductor of the electricity.
Brake are one the key parts of any vehicle, without which it
is basically impractical to use the vehicle for travel. Clearly,
a brake, which serves to slow the vehicle, should not be
excessively weak. in any case, strikingly, when designing a
Braking mechanism, it ought to likewise be taken care that it
is not very productive. An excessively solid a brake would
open us consistently to the ill effects of a sudden brake
application in transport or auto. on the off chance that a vehicle is halted unexpectedly
or strongly, the traveler may hit the front seat or whatever
is there. Thus, excessively productive a brake system isn't required.
3. Hydraulic Brakes
Hydraulic braking system follows a simple principle where the forces applied at one point is
transmitted to another through an incompressible fluid. In this system, we address this
incompressible fluid as break liquid. In hydraulics, the initial force applied to operate the
system multiplies through the process. Times of multiplication can be found by the point on
each end. For instance, the pistons which drives the
fluid is comparatively smaller than the piston that
operates the brake pad, this way the force is multiplied
resulting in efficient and convenient braking. The Pipe
containing the fluid can be of any size length or shape
which allows it to travel through the system anywhere.
It is also possible to split them, therefore allowing them
to connect to master cylinder and two or more slave master cylinder if required.
Figure 9: Hydraulic Brake
Figure 8: Electric Brake
Etrailer
YouTube
12. HYDRAULIC BRAKING SYSTEM
12
4. Mechanical Brakes
They are most normal and can be separated extensively into "shoe" or
"pad" brakes, using an explicit wear surface, and hydrodynamic brakes, such as parachutes, w
hich utilize contact in a working liquid and don't expressly wear.
Basic arrangements incorporate shoes that a contract to rub
outwardly of a rotating drum, for example, a band brake; a rotating
drum with shoes that extend to rub the inside of a drum, normally
called a "drum brake", Other drum designs are possible; such as
rotating caliper which is connected to pads which pushes rotating disc hence the name disc
brake is given to the system. The principle behind frictional braking is it generates heat when
friction force is applied to the braking system which apposes the motion by giving reduction
in velocity. In frictional braking kinetic energy gets converted into thermal energy when
applied to the moving parts of the vehicle.
5. Vacuum Brakes
Air brakes and vacuum brakes are controlled by a brake pipe that connects the braking device
in every vehicle and the brake valve. Each vehicle braking operation is different depending
upon the state of vacuum created inside the pipe by an ejector or exhauster. Ejector- Steam or
Exhauster- electric power on trains removes atmospheric
pressure formed in the pipes and creating vacuum. When
the brake is released then it has full vacuum, the
atmospheric pressure is present then there is no vacuum the
pressure is applied and braking takes place. Motor driven
exhauster creates and maintains the vacuum. High speeds
and low speeds are the two quantities achieved by using the
exhauster. High speed is to create a vacuum and thus braking
and low speed keep the vacuum at a level and gradual
releasing. This maintains the vacuum from small leaks
and proper functioning for safer and efficient performance.
commons.wikimedi
a.org
Figure 10: Mechanical Brake
Figure 9: Vaccum Brake
13. HYDRAULIC BRAKING SYSTEM
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Working Principle
In this project we have used the principle of Pascal’s Law which says that “Pressure exerted
anywhere in a mass of confined liquid is transmitted undiminished in all directions
throughout the liquid”.
What pascal’s law basically says that in any closed system when the pressure is applied at
one point it should give the same pressure value on the other end of the system.
In above fig.2 we can see the same principle used where
two gas cylinders are there and they are connected to a
closed system at one cylinder when the force is applied
to the piston it moves downward by exerting pressure
on the oil inside the cylinder. When this pressure is
exerted the other cylinder, which is connected to the oil
filled pipe moves upwards due to the same amount of Fig 12: Principle of Braking
pressure which is transferred through the close system
which in this case is oil filled pipe which proves the Pascal’s law relation with pressure.
Working of Hydraulic Braking System
In a braking system, frictional force is used to stop the vehicle which utilizes moving energy
of the vehicle to convert into heat. The frictional force causes resistance between two parts
which depends on types of material in contact and pressure holding them together. In a
hydraulic braking system, incompressible fluid is used to transmit the force applied at one
point to another point. In the disc braking system, there is a metal caliper instead of a drum to
generate frictional force between wheel and shoe. When we put force on the brake pedal it
cause fluid inside the master cylinder to get pressurized. This pressurized fluid then moves
through the hose pipe which is connected to the master cylinder. The fluid from the hose pipe
then reaches to the brake pad which is fixed against brake rotor and puts pressure on it. The
entire pressure of the fluid causes frictional force between rotor and brake pad causing
vehicle to stop.
YouTube
14. HYDRAULIC BRAKING SYSTEM
14
Design procedure
While starting the design, our main concern were the assumptions to be made, like what
should be the value of different variable involved in the design procedure such as coefficient
of friction, pedal force applied by the driver, vehicles gross weight etc. After a lot of detailed
discussions and brainstorming sessions, it was decided to go for a thorough study as well as
survey regarding each and every variable in picture. For example: for deciding the value of
coefficient of friction (µ), a detailed survey was carried out regarding the coefficient of
friction (µ) of all the tires related to off road vehicles such as trucks, tractors, dirt bikes,
commercial ATV’s etc. Once the data was gathered, the value of coefficient of friction was
determined by taking the average of all the value. The coefficient of friction came out to be.
In the similar manner all other variables were determined.
Coming back to our design methodology, our braking system was designed significantly and
effectively. In this system we decided to use a single tandem master cylinder of bore ¾ inch
because of the result of our market survey which was based on many factors such as
availability, cost, bore size, easy replacements, weight etc. We decided to go for a self-design
customised pedal box with swing mount pedals having optimum pedal ratio of 5:1. The main
reasons behind this major change are weight reduction, ergonomics, aesthetics, compactness
and space constraints. Finally coming to the splits, we installed both F/R & diagonal split in
our previous design, we came to conclusion that in case of any failure, F/R split yields better
& safer results as compared to diagonal split.
Designing of various braking components
Brake disc
Brake discs were logical components to design in the early stages of the total system design
because the range of possible diameter is already limited by other parts of the vehicle.
Because the brake circuit is an outboard system, the assemblies dwell inside the rims of the
wheels, the disc diameter is limited by the inner diameter of the rims and the clearance of the
calipers with respect to rims. We are used a 10”-5” rim with a 3”-2” offset.
After modelling the rims in Creo 2.0, we came across the maximum size of the brake disc
around 7 inches. In order to generate the required torque, we decided to use optimum brake
discs of size 175mm for front as well as rear. Static structural as well as thermal analysis was
done.
15. HYDRAULIC BRAKING SYSTEM
15
Master Cylinder
The major decision that has to be made when selecting a master cylinder is whether to use
separate cylinders for the front and rear circuits or to use one tandem cylinder that serves
both. But the problem faced when using two separate cylinders was that it required a bias bar
system. So instead, we used a tandem master cylinder and to create biasing effect we used
calipers of different sizes for front and rear.
Fig 13: Tandem Master Cylinder
After doing a market survey, we found out that the most easily available and smallest tandem
master cylinder was of 3
/4 inches.
Fig 14. Pedal orientation
The above image shows the possible orientation of pedal with respect to master cylinder.
Considering the above two choices we concluded that the first choice was better due to
proper space utilization and ease of mounting
16. HYDRAULIC BRAKING SYSTEM
16
Brake Calipers
Once the master cylinder and brake disc size was decide, the other two parameter, which we
could vary, were pedal ratio and caliper size. Due to dynamic weight transfer, more braking
force is required at the front as compared to rear. Hence, after performing a number of
iterations, we came to a conclusion of using a 38mm bore brake caliper in front and a 32mm
brake caliper in rear. It also ensures proper brake force distribution as well as brake force
balance.
Fig 15: Pedal design & its mounting
To begin the design process views and opinions were taken from each and every individual of
the braking design team. Dimensions and geometry the same was designed in Creo2.0. This
pedal setup was design significantly with optimum dimensions, to keep the robustness &
ergonomics of the entire system intact. It has swing mount pedals with a single tandem
master cylinder of bore ¾ inches. Certain amount of material was removed for improving the
aesthetics without compromising with the strength of different elements of the system.
17. HYDRAULIC BRAKING SYSTEM
17
Stress calculation & analysis:
While designing the brake disc static as well as thermal consideration were taken into
account. Using ANSYS 14.5, thermal as well as static structural analysis were performed.
Brake clamping force, heat flux, rubbing area and total braking time were taken as inputs.
The figures below shows the result obtained.
Fig 16.Stress in Disc Fig 17: Deformation in Pedal
Fig 18.Stresses in Pedal Fig19: Deformation in Pedal
18. HYDRAULIC BRAKING SYSTEM
18
Calculations
Pedal ratio = 5:1
Master cylinder bore diameter = 19.05mm
Brake rotor: Front = 175mm
Rear = 175mm
Weight distribution = 45:55
Total weight = 161 Kg
Wheel base = 56 inches
Drivers weight = 75Kg
C.G height = 17.14”
Static weight distribution: FzF = 105.75 Kg
FzR = 129.25 Kg
Figure 20. Notations of various
parameters
Lf =
FzR∗L
W
= 30.8”
LR = L-Lf
= 25.2”
Ψ =
FzR
W
= 0.55
Dynamic axle load:
FzF , dyn = (1-ψ + χa)W
Where, χ =
C.G height
Wheel base
=
h
L
χ = 0.3060
∆dyn wt transfer = χaW
a = 4.94 m/s2
, a = µg, µ = 0.503
Therefore, ∆dyn =
h
L
* a * W =36.211Kg
FzF,dyn = 141.961Kg (1392.63N)
FzR,dyn = 93.039Kg (912.712N)
Front axle Braking force:
FxF = µ * FzF , dyn = 947.841 N
FxR = µ * FzR, dyn = 638.8988 N
Torque:
TxF =
FxF∗10.33"∗25.4
1000
= 255.7807 Nm
TxF = 127.89036 Nm (single)
TxR =
FxR∗10.33"∗25.4
1000
= 166.6355 Nm
TxR = 83.8177 Nm (single)
System Design:
Master cylinder bore: 19.05mm
Area of master cylinder: 2.85*10-4
m2
Brake rotor;
F: 175mm (72.5mm effective radius)
R: 175mm (72.5 m effective radius)
Caliper front:38mm(area=1134.1149mm2
)
19. HYDRAULIC BRAKING SYSTEM
19
Also,
Vtr
a
= ts
So, Stotal = Vtrtr +
Vtr
2
2𝑎
Where, Vtr = initial vehicle velocity
tr = driver reaction time
ta = brake system application time
ts = braking time
a = deceleration
Now,
Vtr = 40Km/h = 11.11m/s
tr = 1 sec
ta = 0.25 sec
tb = 0.3 sec
a = µ*g=0.7*9.81
a= 6.867m/s2
So,
Stotal = 11.11*1+
11.112
2∗6.867
=20.097m
Leverage efficiency=0.
Fmc = P.R*P.F*0.8
= 1000N
Pmc =
Fmc
Amc
= 35.08489 bar
=3508489.318 N/m2
Fcaliper = Pmc * Acaliper * ηwc
Fcaliper front = 3899.054349 N
Force on disc = 2*0.4*3899.05
= 3119.243479 N
Fcaliper rear = 2765.260575 N
Force on disc = 2*0.35*2765.260
= 1995.682403 N
Torque generated
Torquefront = 226.145122 Nm
Torquerear = 140.3369742 Nm
Torque generated at the front and rear is greater than
the required torque.
STOPPING DISTANCE:
SIMPLIFIED:
Figure 21. Simplified stopping
distance time period
Stotal = Vtrtr+
Vtrt 𝑠
2
20. HYDRAULIC BRAKING SYSTEM
20
DETAILED:
Stotal = Vtr (tr + ta +
tb
2
)+
V1
2
2amax
-
amax∗tb
2
24
=11.11(1 + 0.25 +
0.3
2
) + (
11.112
2∗6.867
) + (
6.867∗0.32
24
)
=15.554 + 8.9873 – 0.02575
Stotal = 24.5155m
TOTAL TIME = tr + ta +
tb
2
+
Vtr
2amax
=2.2089 sec
Sizing of master cylinder:
SIMPLIFIED
VF=4[(Awc)F*(B.F)F+(Awc)R*(B.F)R
=4(907.36+562.954)
VF=5.881256 cm3
Bore diameter of master cylinder used =
19.05mm
Maximum stroke length = 36mm
Vmc =
𝜋
4
* 19.052
* 36
Vmc =10.260cm3
Since Volume of master cylinder is greater
than volume required. Hence, selection of
master cylinder is justified.
DETAILED:
Amc=
2FpLpηpηc[(Awc∗BFr)F:(Awc∗BFr)R∗SL
aWR;2(Awc∗BFr)R∗Pk(1;SL)∗ηc
Where,
Fp= pedal force, N
Lp= pedal lever ratio
Pk= knee point pressure, N/cm2
ηc= wheel cylinder efficiency
ηp= pedal level efficiency
Awc= Area of wheel cylinder
SL= reducer slope
r= rotor radius
R= tyre effective radius
W= vehicle total weight
a = deceleration
Amc=
2FpLpηpηc[(Awc∗BFr)F:(Awc∗BFr)R∗SL
aWR;2(Awc∗BFr)R∗Pk(1;SL)∗ηc
SL=0; ηp=0.8; ηc=0.98; Fp=250N; Lp=5:1;
r= 72.5mm; BFF = 0.8; BFF = 0.7;
(Awc)F=1134.2 mm2
; (Awc)R=804.22mm2
;
R=11.5”; a=0.9; W=235Kg; Pk=0.
21. HYDRAULIC BRAKING SYSTEM
21
Amc=
2∗250∗5∗0.8∗0.98[(1134.2∗0.8∗72.5):(804.22∗0.7∗72.5)∗0
0.9∗2305.35∗292.1
=
1960[65783.6:0]
606053.4615
=212.746670 mm2
Amc =2.1274 cm2
Area of master cylinder selected is 2.85cm2
Detailed Volume Analysis:
5. Pad rotor clearance:
Front Caliper = 115.2347 mm3
Rear Caliper = 81.7067 mm3
Total clearance volume = 115.2347+ 81.7067
=196.9414mm3
=0.1969 cm3
6. Brake line expansion:
VBL=
0.79D3LPL
tE
Where,
D=outer diameter= 4mm
T=wall thickness of pipe= 0.7
E= elastic modulus= 2.05*107
N/cm2
PL=brake line pressure=350.8489N/cm2
L= length of brake line=54”
Therefore,
VBL=
0.79∗(0.4)3∗137.16∗350.8489
0.07∗2.05∗107
VBL =1.69551*10-3
cm3
7. Brake hose expansion:
VH=KH*LH*PL=4.39*10-6
*460*350.8489
VH = 0.7085cm3
1. Master cylinder losses:
Vmc=Kmc*PL
Kmc = specific master cylinder volume
loss cm3
/N/cm2
Vmc= 150*10-6
*350.8489
Vmc=0.05262cm3
2. Caliper deformation:
Vc= KcPL + Vr
Vc = volume loss in caliper, cm3
,
Vr = residual air volume
For diameter between 38 and 60mm,
Kc=482*10-6
dwc-1632*10-6
cm3
/N/cm2
dwc = wheel cylinder diameter, cm,
Kc,F.C= 482*10-6
*3.81-1632*10-6
=204.42*10-6
cm3
/N/cm2
Vc=204.42*10-6
*350.8489+0.31
Vc =0.762cm3
3. Brake pad compression:
Vp=4Σ[(Awc)*Cs*PL]
Awc= wheel cylinder area, cm2
Cs = brake shoe compressibility, cm/(N/cm2
)
=4*19.3842*18*10-6
*350.8489
Vp=0.48966 cm3
4. Brake fluid compression:
VA=Vo+4Σ[(Awc).W] cm3
Vo = brakefluid volume with new shoes, cm3
22. HYDRAULIC BRAKING SYSTEM
22
Where, lo = pushrod travel to overcome
pushrod play
lp = pedal ratio.
Sp = (
4.5363
2.85
+ 0.2) * 5
=8.9585 cm
= 3.5269”
The total travel considering all the losses
is in accepted range. Hence, the selection
of master cylinder is justified.
Vo=master cylinder volume+ volume of front
caliper+ volume of rear caliper+ volume of
rigid brake hose+ volume of flexible brake
hose
Vo= 136.0227 cm3
VFL=VA*CFL*PL
W=wear travel of shoes=0.635 cm
CFL= brake fluid compressibility factor = 5*10-
6
cm2
/N
at 422 K
VA= 136.0227+4(19.3842*0.635)
VA=185.258568 cm3
VFL=VA*CFL*PL
=185.258568*5*10-6
*350.8489
VFL=0.324985
8. Air or Gas in the brake system:
VGL=
VGT
To
(1−Po)
(PL+Po)
VGL=2 cm3
These calculations are done for cold brake;
hence the residual air volume is taken as
2cm3
.
9. Fluid losses in hydrorac (booster)
=0 cm3
Total Volume Requirement:
ΣVi=0.0016955+0.7085+0.05262+2+0
.762+0.48966+0.324985+0.1967
ΣVi =4.5363
Sp=[Σ
Vi
Amc
+ lo] * lp
(
4.5363
+ 0.2)
23. HYDRAULIC BRAKING SYSTEM
23
CFD
For CFD we have considered doing 2-D Analysis in Ansys 18.2
The 2D sketch was drawn in space claim as shown in the figure
1
5
6
4
3
2
1
1. Brake Pedal
2. Fluid Reservoir
3. Master Cylinder
4. Brake line
5. Caliper Pad
6. Disc/Rotor
• Element Size: 1
mm
• Type of Mesh:
Quads & Trias
• Number of
Elements:
13160
• Number of
Nodes: 13955
Figure 22: 2D Space Model
Figure 23: Mesh
24. HYDRAULIC BRAKING SYSTEM
24
We can see that if we apply a force of 35 bar at the inlet we get the output as 28.69
bar
The force is found to be 3900 N at the caliper end
Thus the braking efficiency is optimized for the this system
Fig. 24:OEM Brake System
25. HYDRAULIC BRAKING SYSTEM
25
We can see that if we apply a force of 35 bar at the inlet we get the output as 22 bar
The force is found to be 3100 N at the caliper end
Thus the braking efficiency is less than compared to the Braking system already there
in the market.
Input Output
Pressure
35.08489 bar 22.35 bar
Force
3100.90N
Fig 25: Customize Brake System
26. HYDRAULIC BRAKING SYSTEM
26
Conclusion:
The hydraulic brake system should follow the Pascal’s law, which in turn
doesn’t happen due to all the losses in the braking system during actual
braking. Therefore we considered a braking system of a vehicle which is
currently there in the market and calculated the pressure at caliper end.
Further, we designed our own braking system using Creo 2.0 and calculated
the pressure at the caliper end. We concluded that our design needs to be
more optimized as the results clearly shows that the efficiency of the OEM
braking system is more than our design.
References:
• Limpert Rudolf (2011), “Brake design and Safety”, Society of
Automotive Engineers, Inc.
• Walker James (2005), “The Physics of Braking system.” Stop tech:
High performance braking system
Software’s used:
• PTC Creo 3.0
• Solidworks
• Space Claim
• Ansys 18.2
Future Work:
• To Improvise Design by modifying the design
• To perform the transient CFD Analysis on the system to calculate
more accurate results.