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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