MAJOR PROJECT

DESIGN AND ANALYSIS OF VACUUM BRAKE

Department of SYSTEM
Mechanical Engineering
National Institute Of Technology, Agartala

Submitted by :
21UME125 Vineet
21UME049 G Nivitha Krishnan
UNDER THE SUPERVISION OF:
21UME101 Abhishek Prakash
DR. RAHUL BANERJEE
21UME107 Palak Priyadarshni (ASST. PROFESSOR)
(Group - 26)
 Acknowledgem
ent
I would like to use this opportunity to thank my mentor DR. RAHUL BANERJEE, Assistant
Professor, Department of Mechanical Engineering, NIT Agartala for guiding me throughout
the project duration. I also thank Dr. R.S. Panua, HOD, Department of Mechanical
Engineering, NIT Agartala. I would also like to thank NIT Agartala for providing me an
opportunity to work on this interesting project.

I owe gratitude to various books and online resources for the completion of this project.
These resources have been mentioned in the references.

Finally, I would like to thank all the faculty members of the department of mechanical
engineering and my friends for their constant support and encouragement.
 1 Abstract

2 Introduction

Table Of 3
4
Problem Statement

Minor project recap

Contents 5 Components

6 Simulation using Ansys

7 Workbench
Modal Analysis For Getting Different
frequencies
8 Steady State Thermal Analysis

9 Total Deformation
1 Conclusion
 Abstract
Trains convert their kinetic energy into heat to stop. This is done by
applying friction to the wheels using brake pads. Historically, air and
vacuum brakes were used. Air brakes use compressed air to activate
the brakes, while vacuum brakes rely on a vacuum in a pipe to release
the brakes. Modern systems often combine these principles with
advanced technologies like disc brakes, anti-lock brakes, and
electronic braking systems to ensure safe and efficient train
operations.
 Introduction
• Kinetic Energy Conversion: Moving trains possess kinetic energy that must be

converted to heat energy to stop. This is achieved by applying friction to the wheels

using brake pads.

• Historical Braking Systems: Early railway systems employed air and vacuum brakes.

Air brakes use compressed air to activate the brakes, while vacuum brakes rely on a

vacuum to release them.

• Modern Braking Systems: Modern trains utilize advanced braking systems that

combine the principles of air and vacuum brakes with technologies like disc brakes,
anti-lock brakes, and electronic braking systems.
• Factors Affecting Braking Performance: Factors influencing braking performance

include the coefficient of friction between the brake pads and wheels, wheel adhesion,

and the design of the braking system.

 Problem
The increasing adoption of air brake systems in vehicles presents significant
Statement
challenges and drawbacks for both manufacturers and users.

These challenges include :

• higher initial costs due to the complexity of air brake systems.
• the need for air dryers to remove moisture, which leads to additional expenses
and potential maintenance issues, especially in cold climates where defective
air dryers can cause ice formation.

Air brakes contribute to damaging noise pollution, affecting operators and

bystanders. The steep learning curve for smooth operation hinders their adoption.
Addressing these issues is vital for improving air brake systems in the automotive
industry for enhanced efficiency, safety, and cost-effectiveness.
 Minor Project
• The minor project delved into the fundamental principles of railway braking systems,

Recap
focusing on the historical evolution of air and vacuum brakes. It explored the physics

behind kinetic energy conversion into heat through friction, highlighting the role of braking

materials. The project also discussed the operational mechanisms of air and vacuum

brakes, including the creation and maintenance of vacuum in the brake pipe.

• Additionally, the project identified key challenges associated with air brake systems,

such as high initial costs, maintenance requirements, noise pollution, and the steep

learning curve for operators. These challenges underscore the need for innovative

solutions to improve the efficiency, safety, and environmental impact of air brake

systems and why Vacuum Brake system is a better alternative with new changes made

to it.
 COMPONENTS OF THE VACCUM
BRAKE -SYSTEM
This diagram shows the principal parts of the vacuum brake system as applied to an
electric or diesel train. The systems used on steam locomotives were somewhat
different.
 Simulation using Ansys
Workbench
1.Create Geometry: Model the 3D piston, including the head, rod, cylinder,
and seals.
2.Meshing: Discretize the geometry into smaller elements for calculations.
3.Material Properties: Assign material properties like density, elasticity, and
thermal conductivity.
4.Boundary Conditions: Define constraints, loads, and initial conditions.
5.Solver Setup: Configure the solver (ANSYS Mechanical or Fluent) with time
steps, convergence criteria, and other settings.
6.Analysis Type: Choose the analysis type (structural, thermal, or FSI).
7.Run Simulation: Execute the simulation, monitoring progress and checking
for errors.
8.Post-Processing: Analyze results using ANSYS post-processing tools,
visualizing parameters like stress, displacement, and temperature.
 MATERIAL PROPERTIES OF CAST
IRON
Property Value (Typical) Units

Young's Modulus (E) 100 - 170 GPa

Poisson's Ratio (ν) 0.21 - 0.29

Thermal Conductivity 50 - 80 W/(m·K)

Coefficient of Thermal Expansion 10 - 13 1/K

Specific Heat Capacity 0.46 - 0.52 J/(kg·K)

Tensile Strength 200 - 400 MPa

Yield Strength 150 - 300 MPa

Compressive Strength 400 - 1000 MPa

Hardness (Brinell) 150 - 250 HB

Melting Point ~ 1,150 - 1,200 °C

 Modal Analysis For Getting
Different frequencies
Modal analysis helps us understand how a structure will respond to
vibrations. It calculates natural frequencies and mode shapes, identifying
potential resonant frequencies. This information is crucial for designing
structures that can withstand dynamic loads and avoid failures.
Steps performed:
1. Import the geometry model.
2. Select the materials and co-ordinate system
3. Mesh it with automatic methods.
4. Apply the stress and fixed support.
5. Get the solution information.
 Ansys Work
1.Mod
al
2. Harmonic
Response
 STEADY STATE THERMAL
ANALYSIS

Steady-state thermal analysis is evaluating the thermal equilibrium of a

system in which the temperature remains constant over time. In other words,
steady-state thermal analysis involves assessing the equilibrium state of a
system subject to constant heat loads and environmental conditions.

Real systems exhibit non-linear steady-state behavior. Non-linear steady-state

analysis is where input parameters are interdependent. In such cases, a solver
must iterate to find a steady-state solution to the governing equations that
satisfy the input parameters.
 STEADY STATE THERMAL
ANALYSIS

IMPORTANCE-

>Prevention of Thermal Damage and Failure

>Energy Efficiency and Sustainability

>Cost Reduction and Economic Benefits

 STEADY STATE THERMAL
ANALYSIS
STEPS PERFORMED-

1).Specify thermal conductivity of material.

2)Select the internal heat source.

3)Define boundary conditions.

4)Set the initial temperature and convection.

5)Generate the mesh and solution information,total heat flux.

 ANSYS WORK
TOTAL HEAT
FLUX
STEADY STATE THERMAL
 TOTAL DEFORMATION

Deformation is the process by which a material changes shape or size

under the influence of external forces, such as tension, compression,
shear, or torsion.When a material experiences deformation, it can
either return to its original shape (elastic deformation) once the load is
removed or undergo permanent changes (plastic deformation) if the
load exceeds the material's yield strength. Some materials may
experience brittle deformation, where they fracture with minimal prior
shape change. Deformation analysis helps engineers understand how
structures and materials respond under different conditions, ensuring
that they can withstand stresses in practical applications like
construction, automotive, and aerospace .
TOTAL DEFORMATION
 EQUIVALENT STRESS

INTRODUCTION-

Equivalent stress, also known as Von Mises stress or distortion energy stress, is a
scalar value used in engineering and material science to represent the combined
effect of different types of stress (tensile, compressive, shear, etc.) in a material
under multi-axial loading.

The equivalent stress is particularly useful when analyzing ductile materials

because it gives an indication of the material's potential for yielding, even when
the stress is not applied along a single axis.
EQUIVALENT
- STRESS
ANSYS WORK
 CONCLUSION
The vacuum brake are more likely considered preferential
over the air brake in locomotive applications largely
because it is cheaper to install on a steam locomotive. Air
brakes necessitated a bulky, noisy, and visually
unappealing steam-powered compressor that consumed a
significant amount of power. In contrast, the vacuum
ejector used in vacuum brakes is a much simpler device. It
possessed the advantage of simplicity in design and the
ability to achieve a partial release, a feature the air brake
lacked without the use of additional equipment.
 CONCLUSION
The vacuum brake are more likely considered preferential over the air brake in locomotive applications largely because it is
cheaper to install on a steam locomotive. Air brakes necessitated a bulky, noisy, and visually unappealing steam-powered
compressor that consumed a significant amount of power. Below are the different data from the analysis part which can be
implemented in vacuum brake system so that it can be widely used like air brake system.

CONCLUSIONS MINIMUN MAXIMUM

TOTAL DEFORMATION 0 0.00067432m

EQUIVALENT STRESS 7.8811*10^6 Pa 5.3846*10^8 Pa

FACTOR OF SAFETY 0.46428 15

 ANALYSIS MINIMUM MAXIMUM

Modal 0 mm 222.36 mm

HARMONIC 0.14 MPa 59.4264 Mpa

RESPONSE

TOTAL HEAT 6.57*10^-15 7.17*10^-12

FLUX W/mm2 W/mm2

STEADY-STATE
0 deg C 600 deg C
THERMAL

MODAL FREQUENCY 1312.3 Hz 15043 Hz

HARMONIC
1 Hz 10 Hz
FUTURE
SCOPE
• Develop vacuum braking using solar and
kinetic energy, promoting eco-friendly
transportation.
• Create customized vacuum braking for
high-speed trains, autonomous vehicles,
and hyperloop systems, enhancing
safety and efficiency.
• Integrate sensors and AI for proactive
maintenance, minimizing failures, and
ensuring passenger and cargo safety.
 References
www. Indian railways. com
www. Railway webpages .com
Bhanot K.L & Sehgal.S.B, “Railway engineering”
Thomas W Birch “Automotive braking systems”
Rohit Jaiswal*, Ravi Bhardwaj, Rajesh Anant, Prakash Kumar Sen
& ,Shailendra Kumar Bohidar from Study of Vacuum Braking
System International Journal of Research (IJR) Vol-1, Issue-10
November 2014 ISSN 2348-6848
Ravi Gupta.,Deepak Kumar Bharti,Pravin Pune3,Nikhil Kumbharde
,Prof. Londhe V.D.from Vacuum braking system Vol-3 Issue-2
2017 IJARIIE-ISSN(O)-2395-4396
THANK YOU
Vacuum Brake System