Practical 7

Subject with code: Automobile Engineering (2181915)

Name of Laboratory: I.C./Auto. Lab.

List of skills to be developed

Students will be able to…

a) Operate four stroke 4 cylinder petrol and diesel engine, Transfer case for 4 wheel drive,
constant mesh and sliding mesh gear box.
b) Calculate fuel consumption of four stroke 4 cylinder petrol and diesel engine, speed
ratios of constant mesh and sliding mesh gear box and efficiency of gear box.
c) Draw valve timing diagram of four stroke 4 cylinder petrol and diesel engine.
d) Operate pintale type atomizer, hand brake, centrifugal clutch, internal expanding shoe
brake and shock absorber.
e) Describe Propeller shaft, differential, rear axle, Suspension and Steering System.
f) Work as a leader of a team.
g) Check the pollution emission limit of petrol and diesel engines.

Title: Study and Demonstration of Automobile Brakes

i. Practical Task:

Study and Demonstration of Internal Expanding Shoe and Hydraulic brake system for
Automobile vehicles.

ii. Practical significant:

Suspension is the system of tires, tire air, springs, shock absorbers and linkages that
connects a vehicle to its wheels and allows relative motion between the two. Suspension
systems serve a dual purpose — contributing to the vehicle's road holding/handling and
braking for good active safety and driving pleasure, and keeping vehicle occupants
comfortable and a ride quality reasonably well isolated from road noise, bumps, and
vibrations, etc. These goals are generally at odds, so the tuning of suspensions involves finding
the right compromise. It is important for the suspension to keep the road wheel in contact
with the road surface as much as possible, because all the road or ground forces acting on the
vehicle do so through the contact patches of the tires. The suspension also protects the vehicle
itself and any cargo or luggage from damage and wear. The design of front and rear suspension
of a car may be different.

iii. Competency /skills:

Students are able to…

a) List types of Automobile Brakes.

b) Explain working and describe construction of various Automobile Brakes.
 c) Compare various Automobile Brakes.
d) Identify name of Automobile Brakes.

iv. Related Theory:

A brake is a mechanical device which inhibits motion, slowing or stopping a moving
object or preventing its motion. Most brakes commonly use friction between two surfaces
pressed together to convert the kinetic energy of the moving object into heat. Other methods
convert kinetic energy into potential energy in such stored forms as pressurized or
pressurized oil. Brakes are generally applied to rotating axles or wheels, but may also take
other forms such as the surface of a moving fluid (flaps deployed into water or air). Some
vehicles use a combination of braking mechanisms, such as drag racing cars with both wheel
brakes and a parachute, or airplanes with both wheel brakes and drag flaps raised into the air
during landing. Almost all wheeled vehicles have a brake of some sort. Some aircraft also
feature air brakes designed to reduce their speed in flight. Friction brakes on automobiles
store braking heat in the drum brake or disc brake while braking then conduct it to
the air gradually. When traveling downhill some vehicles cause. When the brake pedal of a
modern vehicle with hydraulic brakes is pushed against the master cylinder, ultimately
a piston pushes the brake pad against the brake disc which slows the wheel down. On
the brake drum it is similar as the cylinder pushes the brake shoes against the drum which
also slows the wheel down.

INTERNAL EXPANDING SHOE BRAKE

An internal expanding brake consists of two shoes S 1 and S2. The outer surface of the
shoes are lined with some friction material (usually with Ferodo) to increase the coefficient
of friction and to prevent wearing away of the metal. Each shoe is pivoted at one end about a
fixed fulcrum O1and O2 and made to contact a cam at the other end. When the cam rotates, the
shoes are pushed outwards against the rim of the drum. The friction between the shoes and
the drum produces the braking torque and hence reduces the speed of the drum. The shoes
are normally held in off position by a spring. The drum encloses the entire mechanism to keep
out dust and moisture. This type of brake is commonly used in motor cars and light trucks.
 We shall now consider the forces acting on such a brake, when the drum rotates in the
anticlockwise direction. It may be noted that for the anticlockwise direction, the left hand shoe
is known as leading or primary shoe while the right hand shoe is known as trailing or
secondary shoe.

Consider a small element of the brake lining AC subtending an angle δθ at the centre.
Let OA makes an angle θ with OO1. It is assumed that the pressure distribution on the shoe is
nearly uniform; however the friction lining wears out more at the free end. Since the shoe
turns about O1, therefore the rate of wear of the shoe lining at A will be proportional to the
radial displacement of that point. The rate of wear of the shoe lining varies directly as the
perpendicular distance from O1to OA, i.e. O1B.
HYDRAULIC BRAKE SYSTEM
The most common arrangement of hydraulic brakes for passenger vehicles,
motorcycles, scooters, and mopeds, consists of the following:

• Brake pedal or lever

• A pushrod (also called an actuating rod)
• A master cylinder assembly containing a piston assembly (made up of either one or two
pistons, a return spring, a series of gaskets/ O-rings and a fluid reservoir)
• Reinforced hydraulic lines
• Brake calliper assembly usually consisting of one or two hollow aluminium or chrome-
plated steel pistons (called calliper pistons), a set of thermally conductive brake pads and
a rotor (also called a brake disc) or drum attached to an axle.
The system is usually filled with a glycol-ether based brake fluid (other fluids may also
be used).
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.
The following description uses the terminology for and configuration of a simple disc
brake.
 In a hydraulic brake system, when the brake pedal is pressed, a pushrod exerts force
on the piston(s) in the master cylinder, causing fluid from the brake fluid reservoir to flow
into a pressure chamber through a compensating port. This results in an increase in the
pressure of the entire hydraulic system, forcing fluid through the hydraulic lines toward one
or more callipers where it acts upon one or two calliper pistons sealed by one or more seated
O-rings (which prevent leakage of the fluid).
The brake calliper pistons then apply force to the brake pads, pushing them against the
spinning rotor, and the friction between the pads and the rotor causes a braking torque to be
generated, slowing the vehicle. Heat generated by this friction is either dissipated through
vents and channels in the rotor or is conducted through the pads, which are made of
specialized heat-tolerant materials such as Kevlar or sintered.
Subsequent release of the brake pedal/lever allows the spring(s) in the master cylinder
assembly to return the master piston(s) back into position. This action first relieves the
hydraulic pressure on the calliper, and then applies suction to the brake piston in the calliper
assembly, moving it back into its housing and allowing 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.

An example of a hydraulic brake system

Hydraulic brakes transfer energy to stop an object, normally a rotating axle. In a very
simple brake system, with just two cylinders and a disc brake, the cylinders could be
connected via tubes, with a piston inside the cylinders. The cylinders and tubes are filled with
incompressible oil. The two cylinders have the same volume, but different diameters, and thus
different cross-section areas. The one with the smallest diameter is called the master cylinder.
The spinning disc brake will be placed down at the piston with the larger cross-section.
Suppose the diameter of the master cylinder is half the diameter of the slave cylinder, so the
master cylinder has a cross-section four times smaller. Now, if the piston in the master
cylinder is pushed down 40 mm, with 10 newton (N) of force, the slave piston will then move
10 mm, with a force of 40 N.
This force can be further increased by inserting a lever connected between the master
piston, a pedal, and a pivot point. If the distance from the pedal to the pivot is three times the
distance from the pivot to the connected piston, then it multiplies the pedal force by a factor
of 3, when pushing down on the pedal. Now, if we push the pedal 120 mm down, with 10 N of
force, a force of 30 N will then be applied to the master piston, and the slave piston will move
the brake pad by 10 mm, with a force of 120 N.

v. Resource required:

Sr. No. Name of Equipment Quantity

1 Model of internal expanding shoe brake 1
2 Hydraulic brake system 1

vi. Experiments related sample questions:

a) Which models of brakes are available in our lab?

b) Identify said brake.
c) Identify components of given brake.

vii. Assessment scheme:

 a) Attendance
b) Observation
c) viva voce
d) Identify components of layout model available in lab.

viii. Assignments:

1. Explain construction and working of disc brake system with neat sketch.

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 Fig. Disc brake
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2. Explain with neat sketches working of a master cylinder.

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Fig. Master cylinder

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3. Draw neat sketch of Layout of compressed air brake system.

4. Compare a disk brake and drum brake.

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