Final Year Fourth Project

Presentation
“Design Analysis and Fabrication of Single
Piston Floating Caliper of Hydraulic Brake
System”
Project Mentor :- Submitted By :-
Mr. Shwetabh Singh  Keshav Pratap Singh(1502940075)
Assistant Professor  Aditya Kumar Chaturvedi(1502940011)
Department of Mechanical Engineering  Anupam Kumar Patel(1502940036)
 Anuj Bhaskar(1502940035)
 Contents :-
Final Design of all the Sub-System i.e.
 Caliper Casing
 Piston
 Piston Assembly Accessories
 Master cylinder
 Brake Pads
 Bleed Nut
 Benzo Bolt
 Split Pin
 Brake Hose
 Brake Line
 Frame
 Central Shaft
 Brake Disc
 Bearings
CALIPER CASING :-
 Material Selected :- AL 7075-T6
• Optimum STRENGTH to WEIGHT ratio
• Highest yield and ultimate strength in all available Aluminium Alloy series
 Proof Strength - 480MPa
 Tensile Strength – 560MPa

 Finalized casing design :-

Front View Side View

 Cost of various components :-
Component Vendor Name Location Cost
Name Scolarian Racing Coimbatore, Tamil 750 Rs/kg
Al 7075 T6 Nadu
Mild steel box Mallinath Metal Ghaziabad, Uttar 60 Rs/kg
section Pradesh
Caliper kit Ebay Online platform 59.99£
Brake disc Asap hardware sol. Delhi Rs 400
Master cylinder Sharma Car House Kashmiri Gate Rs 800
Machining Not finalized - Rs 5000(ext.)
 Isometric View

 Different Specifications of casing :-

• Piston Diameter :- 34 mm(Calculated)
• Number of mounting :- 2
• Casing Weight :- 249.14 gms
• Clamping Force :- 5842.7 N(Calculated)
 CAE Analysis(static structural) of casing :-
• Mesh type – 3D Tetrahedral meshing
• Mesh Size – 2mm
• Advance Size Functions
• Force applied on mountings – 5225 N
• Results :-
1. Minimum Factor of Safety – 1.9337
2. Maximum Deformation – 0.15228 mm
Piston Assembly kit :-
 Components in piston assembly kit :-
• Piston – 2
• Dust Seals – 2
• Pressure Seals – 2
• Caliper half joint seals – 2
• Bleed nipple – 2
• Dust caps – 2
• Copper benzo washer – 2
• Grease - 1
 Other finalized accessories :-

1. Brake pads :-
Company :- ASK
Used in rear Caliper of BAJAJ PULSOR 200

2. Bleed Nut :-
Used in BAJAJ AVENGER 150

3. Benzo Bolt :-
Used in BAJAJ AVENGER 150

4. Split Pin :-
Used in BAJAJ AVENGER 150
 Brake hose :-
 Type :- Rubber brake hoses
 Used in AMBASADAR
 Length :- As per requirement

 Master Cylinder :-
 Type :- Single piston
 Company :- OEM BOSCH
 Brake Disc :-
 Material Selected :- Stainless Steel 420
 Number of mountings :- 4
 Pitch circle diameter :- 172 mm
 Coefficient of friction between brake disc and brake pad :- 0.6 (ref. BRAKE
HANDBOOK FRED PHUN)
Decided Layout of Project :-