Design Of Hydraulic Brake System With Variant Bias Using .

International Journal of Applied Engineering Research ISSN 0973-4562 Volume 13, Number 8 (2018) pp. 60-64 Research India Publications. http://www.ripublication.comDesign of Hydraulic Brake system with variant bias using single pistonmaster cylinder for All-Terrain VehicleKrutarth TrivediB.E, Mechanical Department, Silver Oak College of Engg. & Tech, Ahmedabad, Gujarat, IndiaMohit SinghB.E, Mechanical Department, Silver Oak College of Engg. & Tech, Ahmedabad, Gujarat, IndiaRipen ShahAsst. Professor, Department of Mechanical Engineering, Silver Oak College of Engineering & Technology, Ahmedabad,Gujarat, IndiaAbstractHydraulic Brake system is provided for All TerrainVehicle that includes optimization of single piston mastercylinder and fixed caliper inputted in self customizedoutboard wheel assembly. As variant torque is need infront and rear wheels, hence designing variable biasHydraulic Brake system, optimizing components helps toreduce weight, cost and manufacturing and to increasebraking efficiency. Key points of wheel assemblycomponents are hollow front stub, tapered section hub andoptimized slotted disc, slotting helps disc to cool down atmuch faster rate. A dual Piston Fixed caliper has beendesigned from material Al-7050 that helps againstcorrosion and other atmospheric effects with easymounting on knuckle. Sintered metallic pads are used thathas fewer tendencies to wear out easily.Fluid is kept, then the brake lines which will connect themaster cylinder to the various brake calipers, brake caliperis the most important part of the whole disc brake systemit is mounted on disc which is connected to the wheel hubassembly. When the driver applies the brakes then themaster cylinder gets actuated then from the mastercylinder the oil with pressure goes into the brake linesforwarded to the caliper and then the caliper gets activatedand the brake pads will move towards the disc and it willstop the vehicle.Outboard configuration of braking is also a veryefficient technique but the disadvantages of it arethebrake lines, calipers. Brake disc are exposed whilemounting it in this configuration which lead to damagefrom obstacles such as rocks and often debris. It alsorequired more space for the mounting of caliper’s andultimately it overall required more space for designing ofwheel hub assembly’s. Inboard configuration is also veryeffective it reduces the weight of the braking system andreduces manufacturing cost & time. In inboardconfiguration the brake disc is mounted on the final drive.Keywords: brake caliper, single piston master cylinder,wheel hub assembly, ATV1. IntroductionBraking system of any ATV consists of a hydraulic discbrake or drum brake. Disc brake consist of a disc which isa part of the wheel hub assembly, caliper which ismounted on the knuckle, master cylinder which willgenerate the amount of pressure that we required to stopATV. The main target that needed to be kept in mind iswhat amount of torque is need for car.Brakes used in the past car consisted many types ofsystem but the most efficient type was drum brake, drumbrake generally consist of a drum in which brake shoe willexpand with the help of mechanical spring and whenbrakes are not actuated the spring gets to its normalposition and the brake shoe will also come to its position.Figure1: Inboard brake systemThere are various disadvantages of this type of brakingsystem if the spring gets affected then the brake shoe willnot get back to its normal position. The efficiency ofdrumbrake is low and it requires service and update veryfrequently. Hydraulic disc brakes are comparatively moreefficient than drum brake. Disc brake consist of a mastercylinder with a reservoir in which hydraulicFigure2: Outboard brake system60

International Journal of Applied Engineering Research ISSN 0973-4562 Volume 13, Number 8 (2018) pp. 60-64 Research India Publications. http://www.ripublication.comParametersTandem Master CylinderBORE STROKECaliper TypeCaliper Piston Dia.Brake Pad AreaCo-officiant of FrictionBetween Pad & Brake RotorBrake Disc Material.Brake Disc dia.Leverage (Brake Pedal)Values0.75” 1.25”Fixed1”1717.04mm²0.45EN 191506:1Figure3: X split used in braking systemWheel Hub MaterialAluminium 7050Brake ConnectionX - SplitCo-efficient of Friction 0.45-0.80Between Road & TyrePedal Force250-750 NTable 1: Input Parameters consideredCALCULATIONS AT 60 KMPH2. Design of braking systemThe main objective of any braking system is to retard themotion of any vehicle or you can say to stop any vehicle.Deceleration is one of the most important part as thevehicle starts decelerating it will tend to stop at any period.The braking system works on converting kinetic energyinto heat energy and thus motion of the vehicle stops. Themain objective of the braking system is to stop a ATVwith the configuration .263254.9716.274.80 8.5250012792374.165579.9227.892.80 4.9775018122530.077904.9639.521.97 2.98X split is preferred over H as it gives straight line steeringstbility even in case of failure of any circuitTable 2: Calculation of Required Pedal ForceP: Pedal forcef: Brake forceF: Braking forceD: Decelerationd: Stopping distanceWeight: 160 kg (352.74 lbs)Speed: 60 km/hr or 16.66m/sAny type of condition (dynamic, static)Analysis of brake pedal at 750 N pedal forcePedal must be directly actuating the master cylinderthrough rigid link. Brakes are mounted on the final driveaxle. Design of pedal must be mounted with goodergonomics as driver can easily access the pedal and wehave take consideration of every size of driver. In ourbraking system consist of two independent hydraulicsystems, each with their own fluid reserves2.1 Brake Pedal Designstress:55.932 mpa deformation:0.4 mm fos:4.29Design of pedal starts with calculation of leverageconsidering enough leverage for brake actuation i.e. 6:1and hence, getting overall length of pedal as 9”. We havedesigned it as per to get the perfect I shaped so that it willgive superior bending strength.Figure 4: FEA of Brake Pedal and result description2.2 Design of Master CylinderA single piston master cylinder has been designed to getthe maximum braking efficiency while decreasing weightto strength ratio this will increase the braking efficiency asthe weight is reduced and we can generate the maximumbraking force required to lock all four wheels. This mastercylinder is compliable of using DOT 3,4,5,5.1.61

International Journal of Applied Engineering Research ISSN 0973-4562 Volume 13, Number 8 (2018) pp. 60-64 Research India Publications. http://www.ripublication.comouter race of the bearing is press fitted in the hub.Mounting disc on hub disc flanges using tapered bolts.Then the hub is positioned on the bearing and then thesecond bearing’s inner race is press fitted on the spindle.Then the nut is tightened on the spindle and a split pin isinserted into the hole made in spindle for positivelylocking the Wheel Assembly. Finally caliper is fitted onknuckle.Figure 5: CAD model of single piston master cylinderThe various forces acting on master cylinder is Pedal force acting on mounting of the mastercylinderForce due to piston inside of master cylinderForce of spring acting to return of pistonPressure exerted by master cylinder to get therequired braking pressure.2.3 Design of Wheel hub AssemblyFigure 6: Wheel front hub assemblyAs shown in the figure the Wheel Assembly consists of thefollowing arings5.6.a. Deep Groove Ball Bearing-Front/RearNut-(1)Cotter/Split Pin-(1)Before understanding the procedure it is important tounderstand how all these components are assembled.Firstly the spindle is taken. The Knuckle is press fitted onthe spindle using Hydraulic press. The hub is taken and the2.3.1 Design of StubFigure 7: Wheel Rear hub assemblyWeight in the front portion 150 kgFirstly the spindle is designed on which other componentssuch as knuckle, bearings and hub will be fitted. At thisstage we cannot decide the actual length of the spindle, sowe just consider the tentative length of the spindle.Weight on one tire 150/2 75 kgForce due to weight of the vehicle 75 9.81 735.850NSyt 654 N/mm2Endurance Limit 412 N/mmLet us consider this weight to be 1000 N.22. Bump force on the tire:At the time of a bump in the surface a force will act on theportion of the spindle which is inside the spindle. Thisforce is obtained from the wheel rate.Bump Force Wheel rate Travel due to bumpIt consists of following steps: Determining the forces acting on the spindle:The forces acting on the spindle are as follows1. Weight of the vehicle:3. Torque on the spindle:Torque mass on the spindle g radius of wheel 129.44 NDuring static and dynamic conditions a constant force ofthe self-weight is acting on the spindle at the part insidethe knuckle. The weight on the one wheel is62

International Journal of Applied Engineering Research ISSN 0973-4562 Volume 13, Number 8 (2018) pp. 60-64 Research India Publications. http://www.ripublication.com2.3.4 Design of brake caliper3. Material SelectionThe fixed calipers were selected for higher brakingefficiency due to the larger clamping force generated byone piston on either side of the disc.ParameterAluminium– 7050 EN-353 EN-24 EN-19UTS(MPa)566892.63 870655YTS(MPa)464648.06 680415Elongation (%)11.226.81325.7Poisson’s0.330.30.30.29RatioA caliper consist of the various things as shown below Caliper bodyMounting bracketPistonRetracting sealFrictional padsBleed pointBenjo pointFluid inletTable3. Properties of selected materials4. ConclusionThe paper shows studies in detail, conceptual design,analysis and optimization of a braking system. We havedesigned braking system with maximum brakingefficiency and with much lesser weight.The piston diameter of 1” was selected and designedthe brake caliper body according to perfect mountingof the caliper to the wheel hub assembly. Wheel hub assembly was optimized by usingFEA analysis and theoretical calculations.Single Master Cylinder was designed keeping inmind the required braking force.Design of caliper was carried out by also takinginto considerations various clearances, propermount and various other things.5. Reference[1] Fundamentals of Vehicle Dynamics – Miliken &Miliken[2] Brake Handbook – Fred Puhn[3] Vehicle Dynamics: Theory & Application – RezaN. Jaza[4] Fisher, V. V. Graubisic, (1998), Designconsideration and durability approval of wheel hub,SAE international, 11-16-1998.[5] S.dhar, (1988), Fracturer analysis of wheel hubfabricated from pressure die aluminium assembly,P. Drucker, J.A.Makyarello. “Management”.Moscow: Publishing House "Williams", 2010.[6] Theoretical and applied fracturer mechanics, vol 109-02-1988Figure 11: CAD model of brake caliperVarious forces acting on the brake caliper are Reaction on caliper due to the pressureapplied at the back of the pistonReaction on the caliper body due to clampingforceFrictional force on pad, transmitted to thefrictional pad mounting.STRESS (F/R): 196.72DEFORMATION (F/R): 0.54FOS (F/R): 1.72Figure 12: FEA result of the brake caliper and resultdescription64

frequently. Hydraulic disc brakes are comparatively more efficient than drum brake. Disc brake consist of a master cylinder with a reservoir in which hydraulic Fluid is kept, then the brake lines which will connect the master cylinder to the various brake calipers, brake caliper is the most important part of the whole disc brake system