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GOVERNMENT POLYTECHNIC COLLEGE
KONAM, NAGERCOIL – 629004
KANYAKUMARI DISTRICT
PROJECT REPORT
ON
HYDRAULIC BRAKING SYSTEM IN
AUTOMOBILE
Submitted in partial fulfillment of the requirement for the award for the diploma
in Mechanical Engineering of the Directorate of Technical Education
Project guided by
A.PRABU, B.E
Submitted By
CHENTHIL RAJAN.C - 11800306
KRISHNA RAVI.S - 11800310
MARIAPPAN.E - 11800311
NAGARAJAN.T - 11800312
NAMBI VELAYUTHAM.G - 11800313
DEPARTMENT OF MECHANICAL
ENGINEERING
2013 – 2014
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1. ABSTRACT
The main objective of his project is to design a Hydraulic braking system
in automobile. In this project is specially designed to demonstrate the
Engineering Students, how the hydraulic braking system is worked.
In this project is to explain it all the parts of hydraulic braking system.
The some parts are sectioned for the use of visually see the parts, how to works
and easy to understand the working of parts.
This project is simple constructed for the purpose of portability,
and this project can be used all Engineering oriented institutions, colleges,
schools, etc.
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4. CONSTRUCTION DETAILS
IT CONSIST OF THE FOLLOWING COMPONENTS
1. MASTER CYLINDER
2. OIL TUBES
3. METERING VALVES
4. BRAKE FLUID
5. BRAKE DRUM
6. BRAKE SHOE
7. WHEEL CYLINDER
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5. WORKING PRINCIPLE
In Hydraulic brake system when the brake pedal or brake lever is pressed,
a pushrod applies force on the piston in the master cylinder causing fluid from
the brake fluid tank to run into a pressure chamber through a balancing port
which results in increase in the pressure of whole hydraulic system. This forces
fluid through the hydraulic lines to one or more calipers where it works upon
one or two extra caliper pistons protected by one or more seated O-rings which
prevent the escape of any fluid from around the piston.
Fig No. 5.1 WORKING PRINCIPLE
The brake caliper piston then applies force to the brake pads. This causes
them to be pushed against the rotating rotor, and the friction between pads and
rotor causes a braking torque to be generated, slowing the vehicle. Heat created
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from this friction is dispersed through vents and channels in rotor and through
the pads themselves which are made of particular heat-tolerant materials like
Kevlar, sintered glass, etc.
The consequent discharge of the brake pedal or brake lever lets the
spring(s) within the master cylinder assembly to return that assembly piston(s)
back into position. This reduces the hydraulic pressure on the caliper lets the
brake piston in the caliper assembly to slide back into its lodging and the brake
pads to discharge the rotor. If there is any leak in the system, at no point does
any of the brake fluid enter or leave.
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3. BLOCK DIAGRAM
Fig No. 3.1
HYDRAULIC BRAKING SYSTEM
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wedge that pushed a set of brake shoes outward against the inside drum. In Disc Brake
Most modern cars have disc brakes on the front wheels, and some have disc
brakes on all four wheels. The most common type of disc brake on modern cars is
the single-piston floating caliper and the number of piston can be more according to its
application. Disc brake consists of three main components. The components are brake
pad, disc rotor and caliper.
i. The brake pads
Brake pads are steel backing plates with friction material bound to the surface.
The surface of the friction material faces the disk brake rotor. When the brake is
triggered, the hydraulically force are applied, the caliper clamps or squeezes the two
pads together into the spinning rotor to slow or stop the vehicle. When a brake pad is in
contact with the rotor can gets heated, it transfers small amounts of friction material to
the disc, turning it dull gray.
Disc brake system is usually consisting of two brake pads per disc rotor. Even
though, racing calipers utilize up to six pads with varying material frictional properties
for optimum performance. Usually, brake pad has a piece of metal on them called wear
indicator shown in Figure 1. This metal piece makes a squealing sound when intact with
disc brake rotor to indicate it is time to change the brake pad as in Figure 2.
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Figure 2.1 Disc Brake Diagram
Brake pads
Brake caliper
Disk rotor
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