BOSCH CHASSIS SYSTEMS INDIA LIMITED

-: INTERNSHIP REPORT:-
Project Title :- Design of Automatic Disc Brake Based on
Antilock Braking System (ABS) Principle
(5 June 2017- 4 September 2017)

Under The Guidance of:-

1) Mr. Hemant Jadhav
2) Mr. Ganesh Giri
3) Mr. Dilip Krishna
4) Mrs. Sushma Patil

Submitted By:-
Sagar Patil
(B.E Mechanical Engineering)

Smt. Kashibai Navale College of Engineering, Vadgaon (BK), Pune

S.No. 44/1, Vadgaon (Budruk), Off Sinhgad Road, Pune-411041
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APPROVAL SHEET

CERTIFICATE

This is to certify that Mr. Patil Sagar Sidramappa has successfully completed the

Internship Project work entitled “Design of Automatic Disc Brake Based on Antilock

Braking System (ABS) Principle” under my supervision, in the partial fulfilment of

Bachelor of Engineering (Mechanical Engineering), by Savitribai Phule Pune University.

Mr. Hemant Jadhav

(Head, QMM Dept)

Mr. Ganesh Giri Mr. Dilip Krishna Mrs. Sushma Patil

( ) ( ) ( )
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ACKNOWLEDGEMENT

I would take this opportunity to thank all associates for giving this valuable and important
exposure in BOSCH Chassis Systems India Limited, Chakan, Pune. It has been a great
learning experience throughout the period of 3 months. It was indeed my pleasure to work on
this project in this organization.

I would like to thank Mr. Hemant Jadhav (Head, QMM Department), Mr. Ganesh Giri ( ),
Mr. Dilip Krishna ( ) and Mrs. Sushma Patil ( ) for their valuable guidance and time that
they have given me throughout this project. They really gave me practical knowledge and
information which will be very important in my future. They have been mentors and
motivators for me in this important project. I feel happy to work in their organization under
their guidance.

I would also like to sincerely thank Mrs. Neha Parekh (Assistant Manager (HR), BOSCH
Ltd, Chakan, Pune) for giving me this great opportunity to work in BOSCH for 3 months
which turned into a fruitful experience.
I am extremely thankful to Dr. Amar Pandhare (Head, Mechanichal Department, Smt.
Kashibai Navale College Of Engineering, Pune), Mr. Ganesh Dave (Professor, Department
of Mechanical Engineering, Smt. Kashibai Navale College Of Engineering, Pune) for
providing me opportunity to work in, without which this work would not have been possible.
Lastly, I would thank to all the people who directly or indirectly were part of my project and
helped me to successfully complete my project.

Sagar Patil
(B.E Mechanical Engineering)
(Sinhgad Technical Education Society’s

Smt. Kashibai Navale College of Engineering, Pune )

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Preface

Internship is the integral and basic requirement of all the engineering study programs.
Because it is the practical implication of the theoretical knowledge which we have taught
in our engineering subjects to gain further knowledge and experience about professional
business activities. It equips us with the necessary knowledge, skills and values of
business culture which are basic requirement of the business professional and which also
helps new graduates to perform professionally as they get first step in their practical
professional life.
For this reason I was placed at Bosch Chassis Systems India Limited, Chakan, Pune.
Where I have done my 3 months internship. During my internship tenure I have gained a lot
of knowledge about Advanced Braking Systems under the supervision and guidance of my
Internship Supervisors.

My internship report contains all the knowledge which I have learnt there. During our
internship we have learned a lot about Advanced Braking System. Every topic from crust to
core was explained to us and this report is an overview of what we learned. Information in
this report is gathered from different sources like instruction manual, project proposals,
online websites and notes provided by instructors.

I have tried my best to eliminate all mistakes and misrepresentation of facts but since its
natural for humans to make mistakes, so we ask your pardon in advance for any such mistake.

Thank you!
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Abstract

The report covers the following aspects of Internship:-

 Table of contents.

 Introduction to Bosch Chassis Systems India Limited.

 Objective behind the Internship.

 Quality Department of Bosch Chassis Systems India Limited.

 Description of Project at Bosch Chassis Systems India Limited, Chakan, Pune during
Internship.

 Skills & Techniques learned during Internship.

 My role as an Internee.

 Conclusion.
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1) Introduction to Bosch Chassis Systems India Limited:-

Bosch, is a German multinational engineering and electronics company headquartered in
Gerlingen, near Stuttgart, Germany. It is the world's largest supplier of automotive
components measured by 2011 revenues. The company was founded by Robert Bosch in
Stuttgart in 1886.

Bosch entered India in 1922, when Illies & Company set up a sales office in Calcutta. For
three decades, the company operated in the Indian market only through imports. In 1951,
Bosch set up its first manufacturing plant in India.

In India, Bosch is a leading supplier of technology and services in the areas of Mobility
Solutions, Industrial Technology, Consumer Goods, and Energy and Building Technology.
Additionally, Bosch has in India the largest development center outside Germany, for end to
end engineering and technology solutions.

Currently, Bosch India has a turnover of over $2 billion and over 26000 employees spread
across 10 locations and 7 application development centers. 84% of Bosch India revenues
come from its automotive business, with the remaining 16% split between its non-automotive
businesses that include packaging, energy and building solutions, power tools and consumer
retail. Bosch also has an R&D facility in Coimbatore and Bangalore, India. This is Bosch's
largest R&D facility outside its home market of Germany. In September 2014, Bosch
announced the launch of a locally developed eye-care solution in India. The company’s new
eye screening and detection system offers a combination of hardware and software and
provides affordable eye care.

The Bosch Group operates in India through nine companies, viz Bosch Limited, Bosch
Chassis Systems India Limited, Bosch Rexroth India Limited, Bosch Engineering and
Business Solutions Private Limited, Bosch Automotive Electronics India Private Limited,
Bosch Electrical Drives India Private Limited, Bosch Home Appliances Private Limited,
ETAS Automotive India Private Ltd. and Robert Bosch Automotive Steering India Pvt. Ltd.

Bosch's Core Products are:-

 Brakes

 Household Appliances

 Power Tools

 Security Systems

 Fuel Systems

 Controls
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 Electrical Drives,

 Generators

 Starter Motor

 Steering System

2) Objective Behind the Internship:-

 Working closely among other staff like Designers, Project managers, Developers,
Systems analysts, Quality Manager.
 Recognize and set particular quantifiable objectives for team leaders.
 Data collecting and analysis in the dissimilar functions of the distribution center.
 Proactively initiates, expands and sustains efficient working rapport among team
members.
 Attending professional meetings and representing the company or association at other
procedures.
 Study best in class tools and methodologies for dimension of labor.
 Data analysis and summarizing utilizing engineered standard building devices.
 Execution of latest methods and technologies.
 Contribute in formal appraisals and coach development.
 Interfacing among engineering employees, procurement, regulatory, external suppliers.
 Conversing and solving evils among quality, purchasing, manufacturing and advertising
divisions.
 Analysis of recent operations and recognize chances for development.
 Increasing existing programs by evaluating and recognizing areas for alteration.
 Incorporation existing software products and receiving mismatched platforms to work
together.
 Assess engineering drawings, suggestions and plan comments for sound electrical
engineering conformance and practice with recognized safety and design criteria, and
advice approval or disapproval.
 Providing technical support to both the working and maintenance staff.
 Contribution in and conducting every day meetings and appraisals to make performance
in the field.
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3) Quality Department of Bosch Chassis Systems India Limited:-

The Quality Department supports the divisions’ Quality management with the planned
measures by providing a summary analysis of the opportunities and risks related to target
achievement. The “Code of Business Conduct” shapes the foundation of values-based
behavior at Bosch. It is distributed to all associates and outlines the fundamental behavioral
rules they are expected to observe. It also addresses ethical topics, and explains how Bosch
expects associates to handle insider information as well as rules relating to gifts.
Quality management ensures that an organization, product or service is consistent. It has four
main components: quality planning, quality assurance, quality control and quality
improvement. Quality management is focused not only on product and service quality, but
also on the means to achieve it. Quality management, therefore, uses quality assurance and
control of processes as well as products to achieve more consistent quality.
Customers recognize that quality is an important attribute in products and services. Suppliers
recognize that quality can be an important differentiator between their own offerings and
those of competitors (quality differentiation is also called the quality gap). In the past two
decades this quality gap has been greatly reduced between competitive products and services.
This is partly due to the contracting (also called outsourcing) of manufacture to countries like
India and China, as well internationalization of trade and competition.

Quality Objectives:-
 Maintain improving trend of Customer Satisfaction.
 Continual improvement in ‘on-time delivery’ of products as per
customer requirements.
 Adherence to applicable statutory & regulatory requirements
 Adherence to Environment, Health & Safety (EHS) requirements at workplace &
Continuous improvement in house-keeping (5S).
 Constantly monitor suppliers quality and guide them in improvements.
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4) Project Description:-
4.1) Overview of Disc Brakes:-
4.1.1) Introduction to Brakes:-
A vehicle requires a brake system to stop or adjust its speed with changing road and traffic
conditions. The basic principle used in braking systems is to convert the kinetic energy of a
vehicle into some other form of energy. For example, in friction braking it is converted into
heat, and in regenerative braking it is converted into electricity or compressed air etc. During
a braking operation not all the kinetic energy is converted into the desired form, e.g. in
friction braking some energy might be dissipated in the form of vibrations.

Two type of friction brakes, drum brakes and disc brakes, are widely used. Disc brakes as
compared to drum brakes cool faster, due to larger swept area and relatively higher exposure
to air flow, and show self-cleaning ability due to centrifugal forces. Due to these reasons and
some other advantages disc brakes have become the universal.
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Disc Brakes:-

In a disc brake system, a set of pads is pressed against a rotating disc and due to friction, heat
is generated at the disc-pad interface. This heat ultimately transfers to the vehicle and
environment and the disc cools down. A simplified disc brake is shown in figure 1 with the
terminology which is in common use. The pad which is nearer to the center of the vehicle is
called the inboard pad while the one that is away is called the outboard pad. Similarly friction
surface of the disc which faces towards vehicle is called inboard cheek and the one which
faces away is called outboard cheek. The edge of the pad which comes into contact with a
point on disc surface first is called leading edge while the edge which touches that point last
is called trailing edge. The edge of the pad with smaller radius is called inner edge while the
one with larger radius is called outer edge.

4.1.2) Construction of Disc Brakes:-

4.1.2.1) Brake disc:-

Brake disc, also called brake rotor, is fixed to the axle, so it rotates with the same speed as the
wheel. Braking power of a disc brake is determined by the rate at which kinetic energy is
converted into heat due to frictional forces between the pad and the disc. For an efficient
brake design, it is also important that heat is dissipated as quickly as possible otherwise the
temperature of a disc might rise and affect the performance of a disc brake. So to get an
optimum performance in demanding applications, ventilation is introduced in the brake discs
which increases the cooling rate.
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Brake discs could be divided in two categories:

1. Solid brake discs

2. Ventilated brake discs
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Figure 3: Arcuate vane design, arrows show air flow direction for counter clockwise rotation
of disc

4.1.2.2) Brake Pads:-

A brake pad consists of a friction material which is attached to a stiff back plate. Figure 4
shows a brake pad attached to a back plate. Sometimes the friction material and back plate
together are called a brake pad. A brake pad usually incorporates slots on its face and
chamfers at the ends. Figure 5 shows different configurations of pads. A pad can have more
than one slot and it could be arranged in different orientations. One purpose to incorporate
chamfers and slots is to reduce squeal noise. Relatively higher temperature at the pad surface
than the interior will result in convex bending of the pad. A slot will allow the material to
bend and help avoid cracks. Furthermore it facilitates to clean the dust collected between disc
and pad surfaces by offering an escape.
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Figure 4: An assembly of pad, back plate and shim.

Figure 5: Schematic representation of different configurations for a brake pad.

4.1.2.3) Brake caliper:-

A brake caliper is an assembly which houses the brake pads. In addition it also
houses the pistons and provides the channels for the brake fluid which actuates the
pistons. There are two types of calipers, fixed and floating. A fixed caliper does not
move relative to the brake disc and houses the pistons on both sides of the disc as
shown in figure 6. When pressure is exerted both pistons move and push the brake
pads. A floating caliper houses the piston only on one side of the disc as shown in
figure 7. When pressure is exerted, the piston moves and pushes the inner brake pad.
When the pad contacts the disc surface, caliper moves in the opposite direction so
that outer pad also contacts the disc surface. In this design, inboard pad is also called
piston-side pad and outboard one is called finger-side pad.
In general, the inner and outer pads show different contact pressure distributions and
wear behaviors due to different support and actuation systems and difference in
thermal deformations of inboard and outboard cheeks of a disc.
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Figure 6: Schematic representation of a fixed caliper

Figure 7: Schematic representation of a floating caliper

4.1.2.4) Pistons and Cylinders:-

The most common caliper design uses a single hydraulically actuated piston within a
cylinder, although high performance brakes use as many as twelve. Modern cars use different
hydraulic circuits to actuate the brakes on each set of wheels as a safety measure. The
hydraulic design also helps multiply braking force. The number of pistons in a caliper is often
referred to as the number of 'pots', so if a vehicle has 'six pot' calipers it means that each
caliper houses six pistons.

Brake failure can result from failure of the piston to retract, which is usually a consequence
of not operating the vehicle during prolonged storage outdoors in adverse conditions. On
high-mileage vehicles, the piston seals may leak, which must be promptly corrected.
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Figure 8: Schematic of Pistons and Cylinder

4.1.3) Working of Disc Brakes:-

To put it in simple terms, it works on the principle of hydraulic pressure and Bernoulli’s
principle. For starters in disc brakes there has to be a disc. This is a metal disc with a lot of
crevices and holes through its entire area. The thickness and width depends on the
manufacturer, but for the most basic one, the disc has holes in it. The purpose of those, we
will come to later.

To apply force on the discs there are brake pads or brake calipers. These are nothing but
plates with rough surface attached on both ends of the disc. These pads are connected to a
fluid container which contains the brake fluid that flows in via a brake fluid pipe from the
reservoir located at the handle of the bike on top. Might sound a bit confusing but it really is
not.

When the brake lever is pulled, it might seem like you are applying pressure on the discs, but
in reality you are simply opening up the valve for the fluid from the reservoir to flow
downwards. Since the brake fluid is very viscous, it applies pressure on the brake calipers
with the help of Piston which in turn go on to make contact with the disc and rub it. The more
pressure from the top, the more pressure is generated in the contact force between the disc
and the brake pads and hence the frictional force cause the disc to stop rotating and
accordingly the bike comes to a halt. This is a very simply explanation to the entire process.
Now this is to be considered that when the friction takes place a lot of heat is also generated.
This heat is then given off by the discs via the holes in the disc which allows for an increased
surface area to let off the heat formed. Hence we can see discs that contain petals, are curved,
etc. These are how the disc brakes in motorcycles work. The problems that sometimes occur
and need to be taken care of is that since the force applied on the discs is pretty strong, the
wheels tend to lock up due to the excess pressure. Therefore it is important to make sure the
brakes are applied cautiously and not to be jerked or pumped for proper and smooth stopping.
And since the disc brakes have quite the bite, hence they are becoming a choice for all as we
all know the bikes nowadays are also getting bigger power plants and hence having optimum
stopping power for that has become very important.
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Figure 9: Diagram of Actual Disc Brake

4.2) Overview of Antilock Braking System (ABS):-

4.2.1) Introduction to Antilock Braking System (ABS):-

As the name signifies, the anti-lock braking system is a safety system in cars and other
automobiles that keeps their wheels from locking up and helps their drivers to maintain
steering control. Also referred to as anti-skid braking system sometimes, it enables the wheels
of a vehicle to maintain tractive contact with the ground so that they don’t go into an
uncontrolled skid. With ABS, you have more control on your car during situations such as
sudden braking. Basically, it is designed to help the driver maintain some steering ability and
avoid skidding while braking.

An anti-lock braking system or anti-skid braking system (ABS) is an automotive safety

system that allows the wheels on a motor vehicle to maintain tractive contact with the road
surface according to driver inputs while braking, preventing the wheels from locking up
(ceasing rotation) and avoiding uncontrolled skidding. It is an automated system that uses the
principles of threshold braking and cadence braking which were practiced by skillful drivers
with previous generation braking systems. It does this at a much faster rate and with better
control than many drivers could manage.
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Figure 10: Diagram of Actual ABS

4.2.2) Working Principle of Antilock Braking System (ABS):-

The basic theory behind anti-lock brakes is simple. It prevents the wheels from locking up,
thus avoiding uncontrolled skidding. ABS generally offers improved vehicle control and
decreases stopping distances on dry and slippery surfaces. A skidding wheel (where the tire
contact patch is sliding relative to the road) has less traction (grip of the tire on the road) than
a non-skidding wheel. For example, if your car drives over a road covered in ice, it is unable
to move forward and the wheels will keep spinning, since no traction is present. This is
because the contact point of the wheel is sliding relative to the ice.

ABS modifies the brake fluid pressure, independent of the amount of pressure being applied
on the brakes, to bring the speed of the wheel back to the minimum slip level that is
mandatory for optimal braking performance.

ABS generally offers improved vehicle control and decreases stopping distances on dry and
slippery surfaces; however, on loose gravel or snow-covered surfaces, ABS can significantly
increase braking distance, although still improving vehicle steering control.
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Figure 11: Diagram of Working Principle of ABS

4.2.3) Construction of Antilock Braking System (ABS):-

ABS has four major components:-

1) Wheel Speed Sensor
2) Valves
3) Electronic Control Unit (ECU)
4) Hydraulic Control Unit

Figure 12: ABS Exploded View

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1) Wheel Speed Sensor:-

A speed sensor is used to determine the acceleration or deceleration of the wheel. These
sensors use a magnet and a Hall Effect Sensor, or a toothed wheel and an electromagnetic
coil to generate a signal. The rotation of the wheel or differential induces a magnetic field
around the sensor. The fluctuations of this magnetic field generate a voltage in the sensor.
Since the voltage induced in the sensor is a result of the rotating wheel, this sensor can
become inaccurate at slow speeds. The slower rotation of the wheel can cause inaccurate
fluctuations in the magnetic field and thus cause inaccurate readings to the controller.

This sensor monitors the speed of each wheel and determines the necessary acceleration and
deceleration of the wheels. It consists of an exciter (a ring with V-shaped teeth) and a wire
coil/magnet assembly, which generates the pulses of electricity as the teeth of the exciter pass
in front of it.

Figure 13: Schematic of Wheel Speed Sensor

2) Valves:-

The valves regulate the air pressure to the brakes during the ABS action. There is a valve in
the brake line of each brake that is controlled by the ABS.  In the first position, the brake
valve is open and it allows the pressure from the master cylinder to be transferred to the
brakes. In the second position, the brake valve remains closed and pressure from the master
cylinder to the brakes is constrained.  In the third position, the valve releases some of the
pressure on the brakes.
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The third step is repeated until the car comes to a halt. The resistance that you feel when
braking suddenly at high speeds is actually the brake valves controlling the pressure that is
being transferred to the brakes from the master cylinder.

There is a valve in the brake line of each brake controlled by the ABS. On some systems, the
valve has three positions:

 In position one, the valve is open; pressure from the master cylinder is passed right
through to the brake.
 In position two, the valve blocks the line, isolating that brake from the master cylinder.
This prevents the pressure from rising further should the driver push the brake pedal
harder.
 In position three, the valve releases some of the pressure from the brake.

The majority of problems with the valve system occur due to clogged valves. When a valve is
clogged it is unable to open, close, or change position. An inoperable valve will prevent the
system from modulating the valves and controlling pressure supplied to the brakes.

Figure 14: Diagram of ABS Valves

3) Electronic Control Unit (ECU) :-

The ECU is an electronic control unit that receives, amplifies and filters the sensor signals for
calculating the wheel rotational speed and acceleration. The ECU receives a signal from the
sensors in the circuit and controls the brake pressure, according to the data that is analyzed by
the unit.

The controller is an ECU type unit in the car which receives information from each individual
wheel speed sensor, in turn if a wheel loses traction the signal is sent to the controller, the
controller will then limit the brake force (EBD) and activate the ABS modulator which
actuates the braking valves on and off.
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Figure 15: Diagram of ECU

4) Hydraulic Control Unit:-

The Hydraulic Control Unit receives signals from the ECU to apply or release the brakes
under the anti-lock conditions. The Hydraulic Control Unit controls the brakes by increasing
the hydraulic pressure or bypassing the pedal force to reduce the braking power.

The pump in the ABS is used to restore the pressure to the hydraulic brakes after the valves
have released it. A signal from the controller will release the valve at the detection of wheel
slip. After a valve release the pressure supplied from the user, the pump is used to restore a
desired amount of pressure to the braking system. The controller will modulate the pumps
status in order to provide the desired amount of pressure and reduce slipping.
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Figure 16: Layout of Hydraulic Control Unit

4.3) Project Work Description:-

In conventional disc brake when brake is applied, brake pads remains always in contact with
rotor of wheel until which brake is applied and due to this there is a possibility of wheel
locking which in turn may cause serious accident due to wheel locking or skidding.
In this Project, our prime motto is to avoid a locking of wheel and to deliver a safe braking
along with cost efficiency.
Our project is mainly based on Antilock Braking System Principle (ABS) principle which
states that, the anti-lock braking system is a safety system in cars and other automobiles that
keeps their wheels from locking up and helps their drivers to maintain steering control. Also
referred to as anti-skid braking system sometimes, it enables the wheels of a vehicle to
maintain tractive contact with the ground so that they don’t go into an uncontrolled skid.
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In this Project we have designed one metal block assembly which will cut the incoming fluid
6 times per second so that brake is applied 6 times per second thus avoiding a wheel locking.
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4.3.1) Schematic Design of Metal Block Parts:-

1) Top Block:-
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BOSCH CHASSIS SYSTEMS INDIA LIMITED.

TITLE:

TOP BLOCK

Size : DRAWING NO : REV

A3 1
Scale: 2:1 SHEET 1 OF 8

2) Bottom Block:-
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BOSCH CHASSIS SYSTEMS INDIA LIMITED.

TITLE:

BOTTOM BLOCK

Size : DRAWING NO : REV

A3 2
Scale: 2:1 SHEET 2 OF 8

3) Hinge Plate:-
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BOSCH CHASSIS SYSTEMS INDIA LIMITED.

TITLE:

HINGE PLATE

Size : DRAWING NO : REV

A3 3
Scale: 2:1 SHEET 3 OF 8

4) Plate 1:-
 28

BOSCH CHASSIS SYSTEMS INDIA LIMITED.

TITLE:

PLATE 1

Size : DRAWING NO : REV

A3 4
Scale: 2:1 SHEET 4 OF 8

5) Plate 2:-
 29

BOSCH CHASSIS SYSTEMS INDIA LIMITED.

TITLE:

PLATE 2

Size : DRAWING NO : REV

A3 5
Scale: 2:1 SHEET 5 OF 8

6) Inlet-Outlet Port:-
 30

BOSCH CHASSIS SYSTEMS INDIA LIMITED.

TITLE:

INLET-OUTLET PORT

Size : DRAWING NO : REV

A3 6
Scale: 2:1 SHEET 6 OF 8

7) Hinge Bolt:-
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BOSCH CHASSIS SYSTEMS INDIA LIMITED.

TITLE:

HINGE BOLT

Size : DRAWING NO : REV

A3 7
Scale: 2:1 SHEET 7 OF 8

8) Hingle Plate Holding Pin:-

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BOSCH CHASSIS SYSTEMS INDIA LIMITED.

TITLE:

HINGE PLATE HOLDING PIN

Size : DRAWING NO : REV

A3 8
Scale: 2:1 SHEET 8 OF 8

9) Electromagnet:-
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4.3.2) Material Used For Manufacturing of Metal Block:-

Aluminum is used for manufacturing of metal block assembly due to its following properties.
Properties of Aluminum:-
1) Weight
One of the best known properties of aluminum is that it is light, with a density one third that
of steel, 2,700 kg/m3. The low density of aluminum accounts for it being lightweight but this
does not affect its strength.
2) Strength
Aluminum alloys commonly have tensile strengths of between 70 and 700 MPa. The range
for alloys used in extrusion is 150 – 300 MPa. Unlike most steel grades, aluminum does not
become brittle at low temperatures. Instead, its strength increases. At high temperatures,
aluminum’s strength decreases. At temperatures continuously above 100°C, strength is
affected to the extent that the weakening must be taken into account.
3) Linear expansion
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Compared with other metals, aluminum has a relatively large coefficient of linear expansion.
This has to be taken into account in some designs.
4) Machining
Aluminum is easily worked using most machining methods – milling, drilling, cutting,
punching, bending, etc. Furthermore, the energy input during machining is low.
5) Formability
Aluminium’s superior malleability is essential for extrusion. With the metal either hot or
cold, this property is also exploited in the rolling of strips and foils, as well as in bending and
other forming operations.
6) Conductivity
Aluminium is an excellent conductor of heat and electricity. An aluminium conductor weighs
approximately half as much as a copper conductor having the same conductivity.
7) Joining
Features facilitating easy jointing are often incorporated into profile design. Fusion welding,
Friction Stir Welding, bonding and taping are also used for joining.
8) Reflectivity
Another of the properties of aluminium is that it is a good reflector of both visible light and
radiated heat.
9) Screening EMC
Tight aluminium boxes can effectively exclude or screen off electromagnetic radiation. The
better the conductivity of a material, the better the shielding qualities.
10) Corrosion resistance
Aluminium reacts with the oxygen in the air to form an extremely thin layer of oxide. Though
it is only some hundredths of a (my)m thick (1 (my)m is one thousandth of a millimetre), this
layer is dense and provides excellent corrosion protection. The layer is self-repairing if
damaged.
Anodising increases the thickness of the oxide layer and thus improves the strength of the
natural corrosion protection. Where aluminium is used outdoors, thicknesses of between 15
and 25 ¥ìm (depending on wear and risk of corrosion) are common.
Aluminium is extremely durable in neutral and slightly acid environments.
In environments characterised by high acidity or high basicity, corrosion is rapid.

11) Non-magnetic material

Aluminium is a non-magnetic (actually paramagnetic) material. To avoid interference of
magnetic fields aluminium is often used in magnet X-ray devices.
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12) Zero toxicity

After oxygen and silicon, aluminium is the most common element in the Earth’s crust.
Aluminium compounds also occur naturally in our food.

4.3.4) Controller Used for Controlling Electromagnet:-

Controller used in our project is Arduino due to its following specifications.