“HYDRAULIC BRAKING SYSTEM”

GOVERNMENT POLYTECHNIC, PUNE-16

(An Autonomous Institute of Government of Maharashtra)

Department of Mechanical Engineering

Government Polytechnic, Pune.

Seminar report on

“HYDRAULIC BRAKING SYSTEM”

Submitted By

PISAL VIJAY S.

Enrollment No: 1704102

Under the Guidance of

HARIP SIR

Department of Mechanical Engineering

11Government Polytechnic, Pune

 “HYDRAULIC BRAKING SYSTEM”
Government Polytechnic, Pune.

Pune-411016

11Government Polytechnic, Pune

 “HYDRAULIC BRAKING SYSTEM”
GOVERNMENT POLYTECHNIC, PUNE-16

(An Autonomous Institute of Government of Maharashtra)

CERTIFICATE
This is to certify that

PISAL VIJAY S.

Enrollment No: 1704102

Studying in the Fifth semester of diploma in Mechanical

Engineering Has successfully completed the seminar report on

“HYDRAULIC BRAKING SYSTEM”

HARIP SIR Mr. N.G.Kulkarni Dr. V. S. Bandal

(Seminar Guide) (Head of Department) (Principal)

11Government Polytechnic, Pune

 “HYDRAULIC BRAKING SYSTEM”

11Government Polytechnic, Pune

 “HYDRAULIC BRAKING SYSTEM”

ACKNOWLEDGEMENT

This is to acknowledge and thanks all the individuals who played a defining role
in shaping this seminar report. Without their constant support, guidance and
assistance this seminar report would not have been completed.

I would personally like to thank my guide Dr.A.A.Gadhikar and Mechanical

Department (GPP) who with such underlying interest reviewed and enclosed this
seminar report.

I would be finding in my duty if I did not make noteworthy mention of the

respected panel of the members on the seminar Committee. Their constant
encouragement and motivation gave me an opportunity to study this topic. Last but
not the least I would like to thank our Principal who created a healthy environment
for all of us to learn in best possible way.

Pisal Vijay S.
En. No. 1704102
T.Y. M.E. IST SHIFT

11Government Polytechnic, Pune

“HYDRAULIC BRAKING SYSTEM”

CONTENTS

 Brakes

 Classification of brakes

 Hydraulic brakes

 Construction of hydraulic brakes

 System Operation

 Master cylinder

 Block diagram of model

 Conclusion

 References

BRAKES
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“HYDRAULIC BRAKING SYSTEM”
A brake is a device by means of which artificial frictional resistance is applied to a moving
machine member, in order to retard or stop the motion of a machine. In the
process of performing this function, the brake absorbs either kinetic energy of the moving
member or potential energy given up by objects being lowered by hoists, elevators etc.

The energy absorbed by brakes is dissipated in the form of heat. This heat is dissipated in
the surrounding air (or water which is circulated through the passages in the brake drum) so
that excessive heating of the brake lining does not takeplace. The design or capacity of a
brake depends upon the following factors
1. The unit pressure between the braking surfaces,
2. The coefficient of friction between the braking surfaces.
3. The peripheral velocity of the brake drum.
4. The projected area of the friction surfaces, and
5. The ability of the brake to dissipate heat equivalent to the energy being absorbed.

Functions of brake:
1. To stop or slow down the vehicle in the shortest possible distance in emergencies.
2. To control the vehicle to be retained when descending a hill.

The major functional difference between a clutch and a brake is that a clutch is used to keep
the driving and driven member moving together, whereas brakes are used to stop a moving
member or to control its speed.

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CLASSIFICATION OF BRAKES

 On the Basis of Method of Actuation

(a) Foot brake (also called service brake) operated by foot pedal.

(b) Hand brake – it is also called parking brake operated by hand.

 On the Basis of Mode of Operation

(a) Mechanical brakes

(b) Hydraulic brakes

(c) Air brakes

(d) Vacuum brakes

(e) Electric brakes.

 On the Basis of Action on Front or Rear Wheels

(a) Front-wheel brakes

(b) Rear-wheel brakes.

 On the Basis of Method of Application of Braking Contact

(a) Internally – expanding brakes

(b) Externally – contracting brakes.

 On the Basis of Method of applying the braking force

(a) Single acting brakes
(b) Double acting brakes

 On the Basis of power transmission

(a) Direct acting brakes
(b) Geared brakes

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What is a Braking System?

Braking system is a means of converting the vehicles momentum (called kinetic energy)
into the heat by creating friction in the wheel brakes. The Heat is then dissipated into the air
and, it is this ability to absorb and dissipate heat that prevents brake fade under severe
conditions.

HYDRAULIC BRAKES

The hydraulic brake is an arrangement of braking mechanism which uses brake fluid,
typically containing ethylene glycol, to transfer pressure from controlling mechanism top
the braking mechanism. In hydraulic system, fluids do not compress or produce any
measurable friction. Also, fluid pressure does not diminish when transferred within a closed
system. That means that if there is no leak in a system, the pressure at the wheels will be the
same as the pressure from the master cylinder.

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“HYDRAULIC BRAKING SYSTEM”

In this braking system, the pedal force is transmitted to the brake shoe by means of a
confined liquid through a system of force transmission. The force is applied to the pedal
which is transmitted to all the brake shoes.

This system is based on Pascal’s law which states that “pressure exerted anywhere in a
confined incompressible fluid is transmitted equally in all directions throughout the fluid.”

This principle is stated mathematically as:

P=ρgh
where P is the hydrostatic pressure (given in pascals in the SI system), or the
difference in pressure at two points within a fluid column, due to the weight of
the fluid.

ρ is the fluid density (in kilograms per cubic meter in the SI system).
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“HYDRAULIC BRAKING SYSTEM”

g is acceleration due to gravity.

h is the height of fluid above the point of measurement, or the difference in

elevation between the two points within the fluid column (in metres in SI).

CONSTRUCTION OF HYDRAULIC BRAKES

The most common arrangement of hydraulic brakes consists of the following:

1. Brake pedal
2. A pushrod
3. A master cylinder assembly
4. Brake caliper assembly usually consisting of one or two hollow aluminum or
chrome-plated steel pistons (called caliper piston), a set of thermally
conductive brake pads and a rotor (also called a brake disc).

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“HYDRAULIC BRAKING SYSTEM”

At one time, passenger vehicles commonly employed drum brakes on all

four wheels. Later, disc brakes were used for the front and drum brakes for
the rear. However disc brakes have shown better heat dissipation and greater
resistance to 'fading' and are therefore generally safer than drum brakes. So
four-wheel disc brakes have become increasingly popular, replacing drums
on all but the most basic vehicles.
Many two-wheel vehicle designs, however, continue to employ a drum brake
for the rear wheel.
In hydraulic braking mechanism, there is a subsequent release of the brake
pedal/lever which allows springs to return the caliper pistons back into
position and relieves the hydraulic pressure on the pistons, allowing the
brake piston in the caliper assembly to slide back into its housing and the
brake pads to release the rotor.
The hydraulic braking system is designed as a closed system: unless there is
a leak in the system, none of the brake fluid enters or leaves it, nor does the
fluid get consumed through use.

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SYSTEM OPERATION
When brake pedal in pressed, the force is transmitted to the brake shoes
through a liquid (link). The pedal force is multiplied and transmitted to all
brake shoes by a force transmission system. Figure 6.1 shows the system of
hydraulic brake of a four wheeler automobile.

It consists of a master cylinder, four wheel cylinders and pipes carrying a

brake fluid from master cylinder to wheel cylinder. The master cylinder is
connected to all the four-wheel cylinders by tubing or piping. All cylinders
and tubes are fitted with a fluid which acts as a link to transmit pedal force
from master cylinder to wheel cylinders.

The fluid filled in the hydraulic brake system is known as brake fluid. It is a
mixture of glycerine and alcohol or caster oil and some additives. Master
cylinder consists of a piston which is connected to peal through connecting
rod. The wheel cylinder consists of two pistons between which fluid is filled.

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“HYDRAULIC BRAKING SYSTEM”
Each wheel brake consists of a cylinder brake drum. This drum is mounted
on the inner side of wheel. The drum revolves with the wheel. Two brake
shoes which are mounted inside the drum remain stationary. Heat and wear
resistant brake linings are fitted on the surface of the brake shoes.

MASTER CYLINDER

The master cylinder is the heart of the hydraulic brake system. It consists of
two main chambers- the fluid reservoir which contains the fluid to supply to
the brake system and the compression chamber in which the piston operates.

The reservoir supplies fluid to the brake system through two ports. The
larger port is called the filler or intake port and is connected to the hollow
portion of the piston between the primary and secondary cups which acts as
piston seals. The smaller port is called the relief, bypass or compensating
port which connects the reservoir directly with the cylinder and lines when
the piston is in the released position. The reservoir is vented to the
atmosphere so that the atmospheric pressure causes the flow through the
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“HYDRAULIC BRAKING SYSTEM”
filler port. The vent is placed in the filler cap. The boot covers the pushrod
and the end of the cylinder to keep it free from foreign matter.

When the brake pedal is depressed, the master cylinder piston moves forward
to force the liquid under pressure into the system. The relief port is sealed
out of the system. The liquid pressure is conducted to the wheel cylinder,
where it forces the wheel cylinder piston outwards. These pistons force the
brake shoes out against the brake drums.
When brake pedal is released, the return spring quickly forces the master
cylinder piston back against the piston stops. Because the fluid in the lines
returns rather slowly, a vacuum tends to form in the cylinder in front of the
piston. This causes the primary cup to collapse to allow the liquid to flow
from the reservoir through the filler port past the piston to fill the vacuum.
When the pedal is in “off” position, the liquid may flow from the reservoir
through the relief port in the master cylinder, supply lines and wheel
cylinders to make up for any fluid that may be lost or to compensate for
shrinkage cooling of the liquid. In this way, a complete column of liquid is
always maintained in between the master cylinder piston and wheel cylinder
pistons.

WHY DISC BRAKES?

Though disc brakes rely on the same basic principles to slow a vehicle
(friction and heat), their design is far superior to that of drum brakes. Instead
of housing the major components within a metal drum, disc brakes use a slim
rotor and small caliper to halt wheel movement. Within the caliper are two
brake pads, one on each side of the rotor, that clamp together when the brake
pedal is pressed. Once again, fluid is used to transfer the movement of the
brake pedal into the movement of the brake pads.

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“HYDRAULIC BRAKING SYSTEM”
But unlike drum brakes, which allow heat to build up inside the drum during
heavy braking, the rotor used in disc brakes is fully exposed to outside air.
This exposure works to constantly cool the rotor, greatly reducing its
tendency to overheat or cause fading. Not surprisingly, it was under racing
circumstances that the weaknesses of drum brakes and the strengths of disc
brakes were first illustrated. Racers with disc brake systems could carry their
speed "deeper" into a corner and apply greater braking force at the last
possible second without overheating the components. Eventually, as with so
many other automotive advances, this technology filtered down to the cars
driven by everyday people on public roads.

CONCLUSION

We have successfully completed the study and calculation portion involved

in our project “Hydraulic Braking System”. We will be fabricating it in the
next semester.

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“HYDRAULIC BRAKING SYSTEM”

REFERENCES
[1] Automobile Engineering R.B.Gupta. ‘Brakes, classification and its
introduction. Page no 9.1-9.6

[2] Kamaraju Ramakrishna. ‘Types of Braking system’. Page no 190-200

[3] http://www.ignou.ac.in/upload/Unit-6-61.pdf Calculation of hydraulic

forces

[4]http://teachersites.schoolworld.com/webpages/MTurner/files/studyguide%
20legacy%20brakes.pdf

[5] www.mdpi.com/journal/energies Hydraulic Braking Design

[6] Hydraulic Brake Design by Dr. Sunil Jha

[7] Hydraulic Brake System Guide PBR

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