Available online at www.ijapie.org INTERNATIONAL JOURNAL OF ADVANCED PRODUCTION AND INDUSTRIAL ENGINEERING IJAPIE-2020-01-143, Vol 5 (1), 25-32 https://doi.org/10.35121/ijapie202001143 IJAPIE Connecting Science & Technology with Management. A Journal for all Products & Processes. | IJAPIE | ISSN: 2455–8419 | www.ijapie.org | Vol. 5 | Issue. 1 | 2020 | 25 | Designing and Analyzing the Brake Master Cylinder for an ATV vehicle Shubham Upadhyaya 1 , Divyam Raj 1 , Kaushal Gupta 1 , Rakesh Chander Saini 2,* , Ramakant Rana 2 , Roop Lal 3 ( 1 Student, Mechanical and Automation Engineering Department, Maharaja Agrasen Institute of Technology, Delhi India, 2 Assistant Professor, Mechanical and Automation Engineering Department, Maharaja Agrasen Institute of Technology, Delhi India, 3 Assistant Professor, Mechanical Engineering Department, Delhi Technological University, Delhi India) *Email: [email protected]ABSTRACT: Braking system is a means of converting momentum into heat energy by creating friction in the wheel brakes. The braking system which works with the help of hydraulic principles is known as hydraulic braking systems. The most frequently used system operates hydraulically, by pressure applied through a liquid. These are the foot operated brakes that the driver normally uses to slow or stop the car. Our special interest in hydraulics is related to the actions in automotive systems that result from pressure applied to a liquid. This is called hydraulic pressure. Since liquid is not compressible, it can transmit motion. A typical braking system includes two basic parts. These are the master cylinder with brake pedal and the wheel brake mechanism. The other parts are the connecting tubing, or brake lines, and the supporting arrangements. The present paper is about designing of Twin master cylinder system for and all-terrain vehicle and doing a feasibility study of its strength using ANSYS. Our work is focused on reducing weight which is one of the factors to increase the efficiency. Reduction in weight and space, due to its compactness. The twin Master cylinder system is a great advancement in braking system for an ATV. 3-D CAD modeling is done using SOLIDWORKS 2017, whereas the analysis of its strength is done using ANSYS. Keywords: Hydraulic System, Brake, Master Cylinder, Analysis, Design, Twin Master Cylinder I. INTRODUCTON Master cylinder is a component of hydraulic braking system and it is just a simple piston inside a cylinder. Master cylinder is the key element of braking system which initiates and controls the braking action. A reservoir is attached to the master cylinder to store brake fluid. A master cylinder having a reservoir and a cylinder formed from a single piece of molded material. Master cylinder is a component of hydraulic braking system and it is just a simple piston inside a cylinder. Master cylinder is the key element of braking system which initiates and controls the braking action. A reservoir is attached to the master cylinder to store brake fluid. A master cylinder having a reservoir and a cylinder formed from a single piece of molded material [1-3]. The master cylinder displaces hydraulic pressure to the rest of the brake system. It holds the most important fluid in your car, the brake fluid. It actually controls two separate subsystems which are jointly activated by the brake pedal. This is done so that in case a major leak occurs in one system, the other will still function. The two systems may be supplied by separate fluid reservoirs, or they may be supplied by a common reservoir. Some brake subsystems are divided front/rear and some are diagonally separated. When you press the brake pedal, a push rod connected to the pedal moves the "primary piston" forward inside the master cylinder. The primary piston activates one of the two subsystems [4-6]. The hydraulic pressure created, and the force of the primary piston
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Available online at www.ijapie.org
INTERNATIONAL JOURNAL OF ADVANCED PRODUCTION AND INDUSTRIAL ENGINEERING
(1Student, Mechanical and Automation Engineering Department, Maharaja Agrasen Institute of Technology, Delhi India, 2Assistant Professor, Mechanical and Automation Engineering Department, Maharaja Agrasen Institute of Technology, Delhi India, 3Assistant Professor, Mechanical Engineering Department, Delhi Technological University, Delhi India) *Email: [email protected]
ABSTRACT: Braking system is a means of converting momentum into heat energy by creating friction in the wheel brakes. The braking system which works with the help of hydraulic principles is known as hydraulic braking systems. The most frequently used system operates hydraulically, by pressure applied through a liquid. These are the foot operated brakes that the driver normally uses to slow or stop the car. Our special interest in hydraulics is related to the actions in automotive systems that result from pressure applied to a liquid. This is called hydraulic pressure. Since liquid is not compressible, it can transmit motion. A typical braking system includes two basic parts. These are the master cylinder with brake pedal and the wheel brake mechanism. The other parts are the connecting tubing, or brake lines, and the supporting arrangements. The present paper is about designing of Twin master cylinder system for and all-terrain vehicle and doing a feasibility study of its strength using ANSYS. Our work is focused on reducing weight which is one of the factors to increase the efficiency. Reduction in weight and space, due to its compactness. The twin Master cylinder system is a great advancement in braking system for an ATV. 3-D CAD modeling is done using SOLIDWORKS 2017, whereas the analysis of its strength is done using ANSYS.
Master cylinder is a component of hydraulic braking system and it is just a simple piston inside a cylinder. Master cylinder is the key element of braking system which initiates and controls the braking action. A reservoir is attached to the master cylinder to store brake fluid. A master cylinder having a reservoir and a cylinder formed from a single piece of molded material. Master cylinder is a component of hydraulic braking system and it is just a simple piston inside a cylinder. Master cylinder is the key element of braking system which initiates and controls the braking action. A reservoir is attached to the master cylinder to store brake fluid. A master cylinder having a reservoir and a cylinder formed from a single piece of molded material [1-3]. The master cylinder displaces hydraulic pressure to the rest of the brake system. It holds the most important fluid in your car, the brake fluid. It actually controls two separate subsystems which are jointly activated by the brake pedal. This is done so that in case a major leak occurs in one system, the other will still function. The two systems may be supplied by separate fluid reservoirs, or they may be supplied by a common reservoir. Some brake subsystems are divided front/rear and some are diagonally separated. When you press the brake pedal, a push rod connected to the pedal moves the "primary piston" forward inside the master cylinder. The primary piston activates one of the two subsystems [4-6]. The hydraulic pressure created, and the force of the primary piston
Shubham Upadhyaya et al., International Journal of Advanced Production and Industrial Engineering
spring, moves the secondary piston forward. When the forward movement of the pistons causes their primary cups to cover the bypass holes, hydraulic pressure builds up and is transmitted to the wheel cylinders. When the brake pedal retracts, the pistons allow fluid from the reservoir to refill the chamber if needed. Electronic sensors within the master cylinder are used to monitor the level of the fluid in the reservoirs, and to alert the driver if a pressure imbalance develops between the two systems. If the brake light comes on, the fluid level in the reservoir(s) should be checked. If the level is low, more fluid should be added, and the leak should be found and repaired as soon as possible [7-11]. The master cylinder displaces hydraulic pressure to the rest of the brake system. It holds the most important fluid in your car, the brake fluid [12]. It actually controls two separate subsystems which are jointly activated by the brake pedal. This is done so that in case a major leak occurs in one system, the other will still function [13-15]. The master cylinder displaces hydraulic pressure to the rest of the brake system. It holds the most important fluid in your car, the brake fluid. It actually controls two separate subsystems which are jointly activated by the brake pedal. This is done so that in case a major leak occurs in one system, the other will still function [16-19]. The two systems may be supplied by separate fluid reservoirs, or they may be supplied by a common reservoir. Some brake subsystems are divided front/rear and some are diagonally separated. When you press the brake pedal, a push rod connected to the pedal moves the "primary piston" forward inside the master cylinder. The primary piston activates one of the two subsystems [20-22]. The hydraulic pressure created, and the force of the primary piston spring, moves the secondary piston forward. When the forward movement of the pistons causes their primary cups to cover the bypass holes, hydraulic pressure builds up and is transmitted to the wheel cylinders [23-26].
II. DESIGN CONSIDERATIONS OF MASTER CYLINDER
The basic information about brake system and its master cylinder, function, purpose, working principle, different shape and size of master cylinder, failure considerations has been taken from automotive brake system. The work done by brake system parts manufacturers tells that cost mold brake master cylinder made of cast iron was used universally in all the old car and light trucks and after that there has been increased research done on improving the mileage of the vehicle by reducing the weight. The research made a way to concentrate on reducing the weight of brake master cylinder by changing the materials [27, 28].
The manufacturers came up with new idea of composite master cylinder having integral body made of aluminum and reservoir made of plastic material and thus reducing the weight when compare to cost mold master cylinder made of cast iron. Those manufacturers are concentrating on reducing weight of master cylinder by changing the material and by changing the type of manufacture [29]. This information gives basic steps for this project in taking reduction of weight further and considering plastic material to design brake master cylinder. The second edition of brake design and safety gives basic design considerations to design safer brakes and its components. The standard of quality of brake technology as changed over the last two decades. The new design can only be achieved through proper research, through the use of sound engineering concepts and testing the results of small design changes. The information provided by the author has helped in considering engineering design concepts, safety considerations, material selection, guides, standards and practices for the project [30].
III. Experiment Calculations
Important Parameters:
Pedal Force applied by driver (FP) = 250 N Pedal Leverage = 4.5 Wheel Torque (Tc) = 161 Nm Brake caliper piston diameter (Dc) = 32 mm Maximum piston travel of caliper (Lc) = 1.5mm Radius of disc (R) = 190 mm
Shubham Upadhyaya et al., International Journal of Advanced Production and Industrial Engineering
Deceleration = 0.8g Coefficient of friction between tire and ground = 0.78 Coefficient of friction between pads and Disc = 0.35 Dynamic weight transfer = 75.66 kg Piston Diameter Calculations: FM = Force on master cylinder
Fm = Fp x l
FC = Force on caliper
Fc = Tc/R
Ac = Area of caliper piston
A = (π /4) x Dc2
P = Pressure in the system
P = Fc/Ac
Am = Area of piston
Am = Fm/P
M = Master cylinder bore diameter
Dm = √ (Am x 4/ π)
Stroke Length Calculations:
V = Volume displaced by caliper piston
V = π x Dc2 x Lc / 4
Lm = Stroke length of master cylinder
Lm = 4 x V / π x Dm2
IV. CAD MODELING
Finite Element Analysis is a practical application of Finite Element Method (FEM). FEM is a numerical technique for finding approximate solutions to boundary value problems for partial differential equations. It uses subdivision of a whole problem domain into simpler parts, called finite elements, and variational methods from the calculus of variations to solve the problem by minimizing an associated error function. Analogous to the idea that connecting many tiny straight lines can approximate a larger circle, FEM encompasses methods for connecting many simple element equations over many small subdomains, named finite elements, to approximate a more complex equation over a larger domain.
A simple structural analysis was performed as the first step to see if components were structurally strong. If a component failed with the loadings, then no need to continue stress or fatigue analysis since the component is
Shubham Upadhyaya et al., International Journal of Advanced Production and Industrial Engineering
not strong enough to be used. The analysis of the various components of the master cylinder was done in ANSYS 16.0 WORKBENCH for meshing as well as solving.
Meshing of all the parts was done in ANSYS. The mesh is generated by using tetrahedron elements of 1 mm size. Mesh quality is further improved by using proximity and curvature function. This improves mesh density where curvature is small or edges are closed in proximity.
Material used is Al 6061 with Syt=350 Mpa,
Poisson’s ratio=0.33 and Density=2700 kg/m3.
The boundary conditions applied are pressure generated in cylinder casing and the axial force applied through the push rod. The casing is fixed at the mounting points. For the braking system consider which is for an ATV the applied braking force is assumed to be 350 N. The force is magnify by the leverage of 4.5 provided by the pedal assembly and 1575 N force is applied by the push rod. Also the maximum pressure generated in system is applied on inner surfaces of casing.
The results of maximum stress and deformation shows that the master cylinder is safe for designed shell and mounting thickness.
Maximum Stress (Cylinder casing) = 177.6 Mpa
Maximum Deformation (Cylinder casing) = 0.02 mm
Maximum Stress (Piston) = 138.52 Mpa
Maximum Deformation (Piston) = 0.0108 mm
V. ANALYSIS
Figure 1: FEM Design analysis step 1
Shubham Upadhyaya et al., International Journal of Advanced Production and Industrial Engineering
Vehicle dynamics have been carefully studied. It included design of rear and front suspension, load transfer calculations, design of springs, selection of bearings and analysis in ANSYS Workbench. The purpose of the paper is not only the designing of suspension and steering of hybrid tricycle but also to provide in depth study to increase the performance of the vehicle in terms of vehicle dynamics. Design features have been proven effective in terms of vehicle dynamics and the results from FEA indicate the real track performance is quite safe.
VII. ACKNOWLEDGEMENT
Authors extend their regards to the Centre for Advanced Production and Industrial Engineering Research (CAPIER) of Delhi Technological University, New Delhi, India, for providing the layout for this research. Authors would also like to acknowledge and give special thanks to the support of “Metrology Lab” and “Research and Development Lab” of Maharaja Agrasen Institute of Technology, New Delhi, India, for providing the facilities for the completion of this work.
REFERENCES
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