BRAKES

Abstract
Brakes are the most important safety subsystem of each vehicle. Brakes play a vital role in controlling
the vehicle speed while avoiding accidents. The process of braking involves conversion of kinetic
energy into heat. The usual system is composed of components applying adequate frictional force
and which are capable of dissipating heat efficiently. The aircraft disk brake system used in WW 2
was adopted for use in automotive vehicles in 1960’s. The disc brakes have good
stopping performance and are usually safer and more efficient than drum brakes.

Introduction

When the brake pedal of modern vehicle with hydraulic brakes is pushed with human effort against
the master cylinder, pressurised fluid transfers the force to frictional brake pads which squeeze the
rotor attached to rotating wheel. Master cylinder, caliper bore selection and pedal ratio are crucial for
braking performance. Comfortable and ergonomic vehicle controls eliminate driver fatigue and
ensures safety during panic braking situations.

Functions of a Brakes

Following are the functions of brakes:

 Reduction of speed
 Prevent unwanted acceleration
 Stopping of vehicle
 Aid manoeuvrability

Process of Braking

Vi
V2

Vf = 0
Distance

Time
Speed

Time
tr ta tb
Acceleration

Pedal
Force
Time
Decel
eratio
n
Time tr represents reaction time from the instant driver sees the obstacle and starts apply load on
brake pedal. A skilled driver usually has a reaction time of 0.7 secs, but an average value of 1s is
acceptable for calculations. Time t a is the duration taken by the hydraulic system to apply force to the
friction pads. Typical range of t a hydraulic brakes is 0.1 - 0.2 s. The deceleration initiates and grows
linearly depending on nature of pedal load, up to a constant value of a s. In the last phase, speed
decreases linearly till the atv comes to a standstill.

Braking Circuit
Brake Pedal Assembly

Pedal has a mechanical advantage of 5:1. It has been manufactured from Al 6061 t6. The supporting
frame is AISI 1020 and is welded to the chassis and delrin bushings are used for packaging. An EN19
threaded stud transfers and distributes load to the two master cylinders. All components are analysed
for safe design, stress and displacement, values of which are within acceptable limits.

Master Cylinder Selection

Two Aluminium 19.05 mm bore master cylinders, having stroke length of 40 mm are chosen for the
primary F/R circuit due to their low weight, compactness and a low pedal ratio requirement. The mc
bore size and stroke is adequate for the fluid volume displacement in the hydraulic system.

Cutting Brakes

All four brakes are simultaneously operated by single pedal connected to two master cylinders. When
cutting brakes are not in operation, it is a typical F/R split braking circuit. Embedded in the rear
braking circuit are two individual hand actuated 12 mm bore master cylinders which are designed to
lock either of the rear wheels. A schematic of the Inline Braking System master cylinder has been
shown in Fig. 8. As the ATV is driven by an open differential this braking system is beneficial in the
case of traction deficiency with one of the powering wheels allowing transmission of power to the
traction rich wheel. The piston housing and hand pedals are manufactured out of Al 6082 t6.
Contained in the housing is OEM piston rebuild kit.
 Fluid Inlet

Force Input

Fluid Outlet

Caliper and Disc Assembly

The 32 mm bore single piston floating calipers are machined out of Al 7050. The caliper houses OEM
piston, oil seal and dust seal. Machined delrin bushings are fitted in the caliper which float over EN19
slider pins mounted on the knuckle. The caliper halves are designed for high structural rigidity and
fatigue strength. The two halves are held together by 2 M6 12.9 Grade bolts.
Considerations for analytical calculations
Initial velocity of atv 40 kmph (11.11 m/s) Vi
Weight of atv 145 Kg W
Height of C.G. 0.52 m h
Wheel Base 1.458 m l
Tyre and ground friction 0.65
Disc and pad friction 0.45

METHODOLOGY–
 The brake system has been designed to lock all the wheels upon a pedal input force of 35 kg.
 Custom calipers have been designed and fabricated to reduce unsprung mass, and permit
flexibility of wheel assembly design.
 Discs were designed from SS 420, which when heat treated, reach 45 HRC and 1400 MPa.
Optimization of the disc was done to aid cooling and reduce unsprung mass. Thermal analysis was
carried out for six braking cycles to ensure proper heat dissipation. Thermal imaging was carried
out to validate heat rise in the brake disc and verify that heat rise was within the operating limits of
DOT3 fluid. Variation of 4% was observed in the experimental value from the analytical value.

Table 4. Design aggregates for brake subsystem

Specifications Value
Pedal Ratio 5:1
Master Cylinder (bore) BYBRE (12.05mm)
Caliper Custom single piston floating
Brake bias 50:50
Pedal Force 350 N
Braking Torque 200 Nm
Average working pressure 35 bar
Maximum system working 70 bar
pressure
Minimum hose burst pressure 810 bar
Minimum hose bend radius 25 mm
Tire ground friction coefficient 0.65 (wet gravel)
Disc pad friction coefficient 0.45
Initial Speed for braking 11.11 m/s
Braking Distance 9.69 m

Table 5. Parameters of caliper

Caliper-Parameters
Material Al 7050-T7451
Bore 32.05 mm ID
Piston 31.95 mm OD
O-Ring C/S 2.9 x 3.6 mm
O-Ring Squeeze [14] 14%
Pads Semi-metallic
Slider Pin EN19 (42CrMo4)
Pad Retainer M6 12.9 HT Bolt

Hydraulic brake hose assemblies for use with non-petroleum-based hydraulic fluids are installed with
maximum safe working pressure of 260 bar with standard end fittings have been used. Hose
manufacturer employed SAE Standard J 1401 which specifies the performance tests and
requirements for hydraulic brake hose assemblies used in the hydraulic braking system of a road
vehicle.