International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 06 Issue: 04 | Apr 2019 www.irjet.net p-ISSN: 2395-0072

Design, Development and Manufacturing of Braking System for ATV

Krishna Chavan1, Chandani Kumari2, Pratiksha Pawar3 , Akshay Bawankar4, U. C. Agashe5
1,2,3,4B.E. student, Dr. D. Y. Patil Institute of Technology, Pimpri Pune-411018 India
5Assistance Professor, Dr. D. Y. Patil Institute of Technology, Pimpri Pune-411018 India
---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - Various factors are so important to Design, 3. LITRETURE SURVEY
Development and Manufacturing of Braking System for All
Terrain Vehicle. The performance of designed brake system [1] Manjunath TV and Dr. Suresh PM did analysis on the
was dependent on some parameter such as weight thermo mechanical behavior of the dry contact of the brake
distribution, deceleration, pedal effort, pressure generation in disc during the braking phase. The coupled thermal
master cylinder, wheels lock sequence etc. Finally, all structural analysis was used to determine the deformation
theoretical results were validated with experimental results. and the von-mises stress established in the disc for the both
The master cylinder being the Heart of braking system and solid and ventilated disc with two different materials to
the whole system built considering its strength. The developed enhance the performance of the rotor disc. A comparison
design of Inboard Braking system results in reduced size of between analytical and results obtained from FEM was done
wheel assembly, reduced weight and effective braking. and all the values obtained from the analysis was less than
their allowable values. Hence the best suitable design,
Key Words: Pedal, Master Cylinder, Brake lines, Caliper, material and the rotor disc was suggested on the
Brake Pads and Rotor. performance, strength and rigidity criteria.
[2] Karthick C and Kumaresan G did research on thermal
1. INTRODUCTION analysis and enhancement of disc brakes. The research is
The braking system depends upon the frictional force to about the fabrication of disc brake and an attempt has been
stop, to control or to prevent the motion [1]. An efficient made ti investigate the material selection, manufacturing
braking system is required to create enough deceleration to process and testing. Thus the results provide better
stop the car as quickly as the driver wishes, without understanding on the fabrication and testing behavior of
exceeding the driver comfort level with regard to the pedal disc brakes and assist the automotive industry in developing
effort and to effectively dissipate the heat generated due to optimum and effective disc brake rotor.
friction. Brakes used can be of Drum or Disc type. Usually [3] Swapnil R. Abhang, and D.P Bhaskar determines,
Disc brakes are used at all four wheels as it can provide instead of having air bag, good suspension systems, good
efficient braking and bear more loads in the scenario of handling and safe cornering, there is one most critical
weight transfer during the deceleration. system in the vehicle which is brake systems. Without brake
Modern cars mostly use hydraulic brakes. Hydraulic brakes system in the vehicle will put a passenger in unsafe position.
use an enclosed fluid to transmit the pedal force to stop the Therefore, it is must for all vehicles to have proper brake
vehicle. Force applied by the driver is multiplied in the system. In this paper carbon ceramic matrix disc brake
braking system by a principle called Pascal’s law. The law material use for calculating normal force, shear force and
states: “a pressure change occurring anywhere in a confined piston force. Also calculating the braking distance of disc
incompressible fluid is transmitted throughout the fluid such brake. The standard disc brake two wheelers model using in
that the same change occurs everywhere.”[2] Friction Ansys and done the Thermal analysis and Modal analysis
between the rotating disc and stationary pads are used as a also calculate the deflection and Heat flux, Temperature of
tool to stop the vehicle within a considerable distance. The disc brake model.
component used in hydraulic braking system are designed
and manufactured according to the requirement of ATV. [4] Thiagu S.M, Varun.N, Lokeshwaran.R The analysis on
the thermo mechanical behavior of the dry contact of the
2. OBJECTIVES OF BRAKING SYSTEM FOR ATV brake disc during the braking phase. The coupled thermal
structural analysis was used to determine the deformation
 To lock all four wheels at a same time and the von-mises stress established in the disc for the both
solid and ventilated disc with two different materials to
 To ensure safety of the driver completely enhance the performance of the rotor disc.
 To improve braking efficiency [5] Aman Sharma, Prakhar Amrute did the research about
the fabrication of disc brake and an attempt has been made
 To reduce accidents to investigate the material selection, manufacturing process
 To reduce the unsprung mass of the vehicle and testing. Thus the results provide better understanding

© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 3605
 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 04 | Apr 2019 www.irjet.net p-ISSN: 2395-0072

on the fabrication and testing behavior of disc brakes and It was thought critical for brake system to be designed such
assist the automotive industry in developing optimum and that the front and rear brakes lock up at the same rates. This
effective disc brake rotor. Would maximize deceleration and reduce the stopping
distance.
4. LAYOUT OF BRAKING CIRCUIT
Braking Force required to stop the vehicle
Speed =16.16m/sec
S.D.(stopping distance) =4.5m
T.M.C. bore Diameter=15.875mm
Acceleration =5.08m/s2
Braking Force = m*a
=200*5.08
=1016N
5.2 Weight distribution
Here,
Ff= Braking Force on Front Wheel
Figure 1. Layout of braking system Fr= Braking Force on Rear Wheel
Tb=Braking Torque
Master cylinder with required dimensions of piston is r= tyre radius
designed to generate appropriate pressure in the brake
FRONT: -
circuit. Pedal ratio is the mechanical advantage provided by
the pedal. Pedal with optimum pedal ratio is used to multiply Splitting Braking force according to weight distribution
the force applied by the driver and transmit it to the master
Ff =1016 N
cylinder. The braking system is separated in two different
independent circuits so that leakage or failure at any point in For single tyre, Ff=508 N
the system can’t affect the whole braking system. Pressure
Tb= r*Ff
generated in master cylinder is carried to the caliper through
the fluid lines. Most brake fluids used today are glycol-ether Tb =0.2921*508
based considering its characteristics like viscosity, boiling
=148.446 Nm
point, corrosion, compressibility. Pistons in caliper push the
brake pads against the rotor to apply frictional force to REAR: -
decelerate and ultimately stop the vehicle by converting
kinetic energy into heat energy. Fr =361.587 N
Tb =0.2921*361.587
5. CALCULATIONS
=105.619 Nm
5.1 Overview of design
5.3 Caliper Bore Diameter
The braking system uses a front/ rear split braking circuit. Here,
Two master cylinders having a bore diameter of 15.875mm Fcp = Force generated by caliper piston
are used. Two fixed single piston calipers on front wheels Fcf = Clamping Force
and one floating dual piston caliper on the rear inboard disc Acp= Area of caliper piston
is used. Bore diameter for front and rear caliper is 34mm Tr = Torque at rear axle
rear and 32mm respectively. The brake calipers are Tf = Torque at Front axle
connected to the master cylinder with the steel braided Reff = Effective radius off rotor
flexible brake lines which ensures that there is no leakage of µ = Coefficient of friction between Rotor and Brake pad
the brake fluid.
Material for the rotor: SS410 FRONT
Material for the brake pedal: Al 6061-T6 Front =28 mm
Material for Brake Caliper: Al 7075-T6 Fcp = P*Acp
Fcp =7750.535 N

© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 3606
 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 04 | Apr 2019 www.irjet.net p-ISSN: 2395-0072

Fcf = 2*µ*Fcp = 4.56/16.66

=2*0.38*7750.535 = 0.27 sec
=5890.406 N Total Stopping Time = 0.27 + Reaction time
Tr = Fcf * Reff = 0.27 +1.5
=5890.406 *0.0735 = 1.77 sec
=432.944 Nm Heat flux = (heat generated*rubbing distance)/t
REAR = 1.584*106 W/m2
Rear =32 mm
Fcp = P *Acp
=5934.003 N Tmax =148.643 °C (Front)
Fcf =2*µ*Fcp Rear rotor diameter = 170 mm
=4509.84 N =0.17 m
Tf =308.924 Nm
5.4 Deceleration and stopping distance
Deceleration is calculated by following formula = 1.476*106 W/m2
W = x.a.m.g
Where, W =weight transfer =584.515 N
a = deceleration (in form of g) Tmax (Rear)= 145.5539
M =mass of vehicle = 200 kg
g =9.81 m/s2 6. DESIGN AND ANALYSIS OF COMPONENT
a = 6.89 m/s2 Brake Disc, Caliper, Brake master cylinder and Pedal were
average acceleration of vehical designed in CATIA V5R21.

aavg = 3.108 m/s2 The analysis of disc and heat flux distribution of Disc,
Deformation in caliper and stress induced in pedal was
Stopping distance is calculated by following formula performed in Ansys 19.1.
S= 4.5 m 6.1 Design and analysis of brake disc
3.7 THERMAL CALCULATION
Mesh size – 2mm
Maximum Speed = 60 km/hr = 16.66 m/s2 Heat Flux (1.476W/mm2) & Radiation (To Ambient)
Kinetic energy =1/2 *m*v2
=1/2 *200*16.662
= 27755.56 J
Total kinetic energy =Heat generated
= 27755.56 J
Area of Rubbing Surface (Front)
= π/4*(Do2 –Di2)
= π/4*(0.162 –0.1142)
= 9.899*10-3 m2
Skid distance for 60 Kmph = 5.767m
Figure 2. CAD Model of Brake Disc
Stopping time = d/ν

© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 3607
 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 04 | Apr 2019 www.irjet.net p-ISSN: 2395-0072

Figure 2. Temperature Analysis Figure 5. CAD Model of Brake Pedal

Figure 3. CAD Model of Self-Manufactured Caliper

Figure 6. FEA Analysis of Brake Pedal
7. CONCLUSION
The brake assembly is one of the most important parts of
any automotive system. The above designed brake assembly
is used in BAJA ATV during BAJA SAE India 2019 and BAJA
SAE International 2019. During the event all four wheels at
lock at the same time and brake test was cleared in the first
attempt itself.
ACKNOWLEDGEMENT
We would like to thank our team members from ‘Team
Durgayans’ for their support during the whole process. We
would also like to thank ‘Vaishnavi Tool Room Pvt. Ltd.
Bhosari’ and ‘Super Enterpises, Bhosari’ for the fabrication of
our brake parts.

Figure 5. FEA Analysis of Caliper

© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 3608
 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 04 | Apr 2019 www.irjet.net p-ISSN: 2395-0072

REFERENCES
AKSHAY BAWANKAE
[1] S. Mishra and S. Jandhu, “Balance bar design and motion
analysis of pushrod”. International Journal of Mechanical
Engineering and Robotics Research. Vol.3, No.3, July 2014.
[2] Aman Sharma1, Prakhar Amrute2, Suryakant Singh
Thakur3, Jatin Shrivastav4 “DESIGN, ANALYSIS AND
FABRICATION OF BRAKING SYSTEM WITH REAR INBOARD
BRAKES IN BAJA ATV” International Research Journal of U. C. AGASHE
Engineering and Technology Volume.05, Issue.05, May 2018.
[3] Theory of ground vehicles, Third edition by J.Y
Wong
[4] Brake design and safety by Rudolf Limpert
[5] Aluminium composite for brake disc, Edition one
by V. Saravanan
[6] Alternate material in automobile brake disc, by
Telang A.K.
[7] Brake Handbook by Rick Baile
[8] University of Cincinnati SAE Baja Race Team by
Mark Schmidt
[9] Bearcats Baja Braking System By Richard T. Best

http://www.iaeng.org/publication/WCE2010/WCE20
10_pp2322 -2326.pdf
https://en.wikipedia.org/wiki/Inboard_brake
https://racemagazine.com.au/topic/inboard-vs-
outboard-rear-brakes
https://www.carthrottle.com
https://www.f1technical.net

BIOGRAPHIES

KRISHNA CHAVAN

CHANDANI KUMARI

PRATIKSHS PAWAR

© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 3609