DEVELOPMENT OF BRAKING SYSTEM IN AUTOMOBILES

Devkar Rohit , Kore Avadhut,Kambale Onkar,Kulkarni Shreehari

Karmayogi Institute of Technology
Shelve Tal Pandharpur Dist Solapur,Maharashtra,India 413304

Devkarrohit254@gmail.com

Abstract—The braking system in a car is a mechanical device that transforms the kinetic energy of the car into heat energy, letting it to stop or slow down. By pressing a pair of shoes on a drum, enough friction is produced to stop the vehicle.During use, the brake drum is subject to severe thermal stress and high temperatures.As a result, it's critical to choose a brake drum material that can handle the tremendous pressure and temperature created. The drum brake must be built with minimal vibration and noise in order to ensure pleasant operation. Uncomfortable discomfort and diminished brake system effectiveness can result from excessive vibrations. This entails taking into account a number of elements, including the drum's size and form, the brake shoes' lining, and the brake application and release mechanism.Drum brakes can successfully withstand high pressure and temperature while minimising vibration and noise by using careful material selection and design concepts. This helps them operate comfortably and dependably in automobiles.

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Key words: Drum brakes, Disc brakes, Air brakes , Air hydraulic brakes , Vacuum brakes, Electric brakes.

Introduction

The earliest motion-prevention and momentum-slowing devices were tested in the 1800s. Over a century later, the braking system has developed into a sophisticated mechanism that can respond to various driving circumstances. The advancement of brake systems has increased safety and decreased the danger of auto accidents worldwide, from the first drum brakes to the present discs. It is difficult to identify the creator of the first braking system because there have been so many variations over the past century; yet, individuals who created these systems all shared the same objective: to enable people to manage a motor vehicle.

Drum brakes have long been a crucial component of vehicle braking systems. They are one kind ofa mechanical braking system that uses friction created by a component in the shape of a drum to slow down or stop a vehicle. Although they can also be employed on the front wheels or in conjunction with disc brakes, drum brakes are typically found on the rear wheels of many automobiles.

A set of brake shoes are forced on the inner surface of a rotating drum as the drum brake's main working mechanism. The friction caused by this contact turns the kinetic energy of the moving object into heat energy. The attached wheel also rotates more slowly as a result of the frictional force that results.

Drum brakes also offer the benefit of being less prone to the buildup of debris, such as water, dirt, or dust. The drum design aids in protecting the brake mechanisms, decreasing the possibility of impurities interfering with the braking action. Drum brakes are especially well suited for applications in off-road vehicles or in tough situations because of this property.

However, compared to disc brakes, drum brakes do have significant restrictions. They can be susceptible to fading under extended or hard braking and are often less effective in dissipating heat. Compared to disc brakes, drum brakes are typically more challenging to service and maintain since the drum must be disassembled in order to access the braking parts.

Drum brakes are nevertheless utilised in a variety of vehicles despite these drawbacks, particularly in the rear wheel locations. They are a good option for many automotive applications due to their dependability, toughness, and capacity to withstand high pressure and temperature. Drum brakes are always improving to improve their performance, lessen vibration and noise, and increase overall braking effectiveness as a result of continual developments in brake technology.

Methodology:

The following methodology might be used to describe the project on drum brakes Review of the literature

To learn more about current drum brake systems, materials, design considerations, heat dissipation strategies, noise and vibration reduction approaches, and friction materials, do a thorough literature review. This review will offer a strong framework for comprehending the current state of the art and pinpointing potential improvement areas.

Analyse the problems with drum brake systems in depth, paying special attention to heat dissipation, braking effectiveness, noise production, and vibration. Based on the literature research and the targeted project objectives, pinpoint the precise areas that need improvement and attention.

Examine various materials that are appropriate for brake shoes and drums based on their strength, thermal conductivity, cost-effectiveness, and durability.

1. Organization of Dissertation

Table 1: Organization of Dissertation

Design:

Fig.1: Drum Brake Design

CATIA V5 is a powerful computer-aided design (CAD) software that allows users to create solid models of various products and components. Solid modeling is a process of creating 3D models of parts or assemblies with real-world properties, such as dimensions, materials, and other physical characteristics. With CATIA V5, users can create solid models of parts or assemblies by using various tools and features. These tools allow users to create sketches, extrude or revolve them to create 3D shapes, and manipulate them to create complex forms. CATIA V5 also provides various tools to help users create and manage assemblies of multiple parts. These tools allow users to assemble different parts together to create a final product, and perform operations such as mating, aligning, and positioning of components. Additionally, CATIA V5 allows users to apply materials and textures to the models, perform simulations and analysis, and create technical drawings for manufacturing and documentation purposes. Overall, CATIA V5 is a powerful tool for solid modeling, providing users with the 24 ability to create complex models of products and components with real-world properties. It offers a comprehensive set of tools and features that can help users streamline the design process, reduce errors, and improve overall productivity. components.

Users can also add materials and textures to the models, run simulations and analyses, and produce technical drawings for use in manufacturing and documentation with CATIA V5. CATIA V5 is a strong solid modelling tool that gives users the capacity to build intricate models of items and components with real-world qualities. It provides a full range of features and tools that users may utilise to speed up the design process, lower mistake rates, and increase overall productivity.

3.WORKING:

Fig.2: Working of Drum Brake

NORMAL BRAKING – When the brakes are applied, brake fluid is forced under pressure from the master cylinder into the wheel cylinder, which in turn pushes the brake shoes into contact with the machined surface on the inside of the drum. This rubbing action reduces the rotation of the brake drum, which is coupled to the wheel. Hence the speed of the vehicle is reduced. When the pressure is released, return springs pull the shoes back to their rest position. AUTOMATIC SELF-ADJUSTMENT – 25 As the brake linings wear, the shoes must travel a greater distance to reach the drum. When the distance reaches a certain point, a self-adjusting mechanism automatically reacts by adjusting the rest position of the shoes so that they are closer to the drum. Here, the adjusting lever rocks enough to advance the adjuster gear by one tooth. The adjuster has threads on it, like a bolt, so that it unscrews a little bit when it turns, lengthening to fill in the gap. When the brake shoes wear a little more, the adjuster can advance again, so it always keeps the shoes close to

the drum. Typically the adjusters only operate when the vehicle is going in reverse and the brakes are engaged. iii. PARKING/EMERGENCY BRAKE - The parking (or emergency) brake system controls the brakes through a series of steel cables that are connected to either a hand lever or a foot pedal. The idea is that the system is fully mechanical and completely bypasses the hydraulic system so that the vehicle can be brought to a stop even if there is a total brake failure. Here the cable pulls on a lever mounted in the brake and is directly connected to the brake shoes. This has the effect of bypassing the wheel cylinder and controlling the brakes directly. A drum brake is a brake that uses friction caused by a set of shoes or pads that press outward against a rotating cylinder-shaped part called a brake drum. The term drum brake usually means a brake in which shoes press on the inner surface of the drum. When shoes press on the outside of the drum, it is usually called a clasp brake. Where the drum is pinched between two shoes, similar to a conventional disc brake, it is sometimes called a pinch drum brake, though such brakes are relatively rare. A related type called a band brake uses a flexible belt or "band" wrapping around the outside of a drum.

Material Selection: The frame materials selected for the machine include the base plate and motor support, which were made using mild steel. There are several reasons for this choice of material:

1. Mild steel is readily available in the market.

2. It is economical to use compared to other materials.

3. It is available in standard sizes, making it easier to work with.

4. It has good mechanical properties, including its machinability.

5. It has a moderate factor of safety, which balances the risk of failure with material wastage.

6. It has high tensile strength.

7. It has a low coefficient of thermal expansion.

Mild steel has a carbon content ranging from 0.15% to 0.30%. It can be easily welded, but hardening is not recommended. Both ultimate tensile and compressive strength increase with increasing carbon content. Mild steel was chosen because it served the purpose and met the required specifications.

Bright material, on the other hand, is machine-drawn and has a good surface finish. The main difference between mild steel and bright metal is that while mild steel plates and bars are forged in a forging machine, bright materials are drawn from dies in a plastic state, resulting in a surface finish that does not have carbon deposits. This makes it suitable for extrusion and formation of engineering materials while retaining their metallic properties.

Material selection is an important consideration in the fabrication of machines. Design engineers must be familiar with the impact that manufacturing processes and heat treatment have on material properties to make the proper selection. The choice of materials depends on several factors, such as availability, suitability for working conditions, cost, physical and chemical properties, and mechanical properties. The mechanical properties of metals are associated with their ability to resist mechanical forces and load, including strength, stress, stiffness, elasticity, plasticity, ductility, brittleness, malleability, toughness, resilience, creep, and hardness. A machine part should be made of a material that has properties suitable for the conditions of operation. The selection of materials depends on the types of stresses set up during operation, the type of load, and the factor of safety, which depends on various factors, such as reliability of properties and applied load, certainty of mode of failure, simplifying assumptions, localized stress, initial stresses set up during manufacturing, and the extent of loss of life if failure occurs.

The selection of the materials depends upon the various types of stresses that are set up during operation. The material selected should with stand it. Another criteria for selection of metal depend upon the type of load because a machine part resist load more easily than a live load and live load more easily than a shock load.

Selection of the material depends upon factor of safety, which in turn depends upon the following factors.

Reliabilities of properties

Reliability of applied load

The certainty as to exact mode of failure

The extent of simplifying assumptions

The extent of localize

Result and discussion:

operate a drum brake system, follow these general instructions:

sure Safety: Before operating the system, ensure that the vehicle is parked on a level surface and the parking brake is engaged. Also, make sure the engine is turned off to avoid any accidental movement.

Familiarize with Controls: Familiarize yourself with the location and operation of the brake pedal, which controls the braking system. The brake pedal is typically located on the floor, to the left of the accelerator pedal.

Aapply Braking Force: To apply the brakes, firmly press the brake pedal with your foot. The force applied to the pedal will transfer to the brake system, causing the brake shoes to press against the drum and generate friction.

Gradual and Smooth Braking: Apply the brakes gradually and smoothly, especially when coming to a stop. Abrupt or harsh braking can cause instability or loss of control, particularly in slippery conditions.

Anticipate Braking Distance: Anticipate the required braking distance based on the road conditions, speed, and traffic ahead. Adjust your speed and apply the brakes early to ensure a safe and controlled stop.

P Brake Usage: When parking the vehicle, engage the parking brake to ensure it remains stationary. The parking brake is typically a separate lever or pedal located near the driver's seat. Follow the specific instructions for engaging and disengaging the parking brake as per the vehicle manufacturer's guidelines.

B Maintenance: Regularly inspect the brake system for any signs of wear, such as uneven braking, noise, or reduced performance. If you notice any abnormalities or suspect brake issues, it is recommended to have the system inspected and serviced by a qualified mechanic.

N The specific instructions for operating the drum brake system may vary depending on the vehicle make and model. Always refer to the vehicle's owner's manual for detailed instructions and follow any specific guidelines provided by the manufactur

Performance analysis and testing methodology for a drum brake system typically involve the following steps:

Test Setup: Set up a controlled testing environment that simulates real-world braking conditions. This may include using a test vehicle or a brake testing rig equipped with the drum brake system. Ensure that the testing equipment and instrumentation are properly calibrated.Brake Performance Testing: Conduct brake performance tests to evaluate the braking capabilities of the drum brake system. This involves measuring parameters such as braking force, deceleration, stopping distance, and pedal feel. Perform tests under different conditions, including varying speeds, loads, and road surfaces, to assess the system's performance in different scenarios.

Heat Dissipation Testing: Evaluate the heat dissipation characteristics of the drum brake system. This can be done by monitoring the temperature of different components during repeated braking cycles or sustained braking. Measure temperature using thermocouples or infrared thermography to identify areas prone to overheating and assess the system's ability to dissipate heat effectively.wear Analysis: Assess the wear characteristics of the brake shoes and other components of the drum brake system. This may involve measuring the thickness of the brake shoe lining before and after testing or conducting accelerated wear tests. Monitor wear patterns and compare them to expected wear rates to evaluate the system's durability and predict maintenance intervals.noise and Vibration Analysis: Analyze the noise and vibration levels produced by the drum brake system during braking. Use sound level meters or vibration sensors to quantify and analyze the noise and vibration signatures. Assess any abnormal noise or vibration patterns and identify potential sources to optimize the system for reduced noise and vibration. parative Analysis: Perform comparative analysis of the drum brake system against benchmark standards or alternative braking systems (e.g., disc brakes). Compare performance metrics such as braking force, heat dissipation, wear rates, noise levels, and cost-effectiveness to evaluate the drum brake system's performance and identify areas for improvement.

CONCLUSION:

In conclusion, drum brakes are a crucial part of many cars' braking systems because they deliver consistent and efficient stopping performance. Drum brakes are essential for slowing or halting a vehicle because they transform kinetic energy into thermal energy.

When braking, the drum brake system, which includes parts like the backing plate, brake drum, wheel cylinder, and brake shoes, generates friction and releases heat. While the brake drum acts as the surface for friction creation and heat dissipation, the backing plate offers structural support and protection. The brake shoes are activated by the wheel cylinder, which transforms hydraulic pressure into mechanical force. The brake shoes then make contact with the drum and produce the necessary friction.

Drum brakes have a number of benefits,of the key components of a drum brake system and their relative positions. The brake drum is shown as a cylindrical component, with the brake shoes pressing against its inner surface. The backing plate provides a solid base for the components and protects them from external elements. The wheel cylinder is depicted as a hydraulic device located within the brake drum, while the adjusting mechanism, return springs, brake springs, and linkage and levers are shown to illustrate their respective roles in the system. Note: The diagram provided is a simplified representation and may not reflect the exact design or configuration of every drum brake system. The specific arrangement and components can vary depending on the vehicle make, model, and manufacturer specifications.

Cost-effectiveness, self-actuation, heat dissipation, improved contaminant sealing, and parking brake operation are just a few of the benefits.

Drum brakes are advantageous for a variety of applications, including heavy-duty vehicles, off-road vehicles, industrial equipment, and light and heavy-duty commercial vehicles.

While drum brakes are still frequently utilised, it's crucial to recognise that disc brakes have become more common because of their greater heat dissipation and braking efficiency. Drum brakes are still a practical and affordable alternative for many automobiles, particularly for low-cost models and uses that need toughness and longevity.

Overall, drum brake development and advancement improve vehicle operation, safety, and dependability by assuring effective braking and improving the driving experience.

REFERENCES

[1] "Development and Analysis of Finned Brake Drum Model for Effective Heat Transfer", IJSEAS - Volume 2, Issue 9, September 2016. Putti Srinivas Rao, D.V.G. Prasad, D.D.S.P.R. Raju, B.R. Phanindra, and B.N. Surya.

[2] Arvind P. Jinturkar and Prof. Vidyadhar R. Bajaj, "Optimisation of Hub Cum Brake Drum for Weight Reduction", Imperial Journal of Interdisciplinary Research (IJIR), Vol. 2, Issue-8, 2016.

[3] Anup Kumar and R. Sabarish, "Structural and Thermal Analysis of Brake Drum," Middle East Journal of Scientific Research, 20(8), 1012–1016 (2014).

[4] "Development and Analysis of Finned Brake Drum Model Using Solidworks Simulation", IJIRSET Vol. 4, Issue 5, May 2015, by Bako Sunday, Usman Aminu, and Paul O. Yahaya.

[5] Amit Phatak and Professor Prasad Kulkarni, "Drum Brake Back plate Analysis and Design Modification to Control Squeal Noise", 2017 IJEDR, Volume 5, Issue 3. [6] K. Balaji Gowthami, "Designing and Analysis of Brake Drum", IJRASET Volume 4 Issue IX, September 2016.

[7] Meenakshi Kushal and Suman Sharma, "Optimisation of Design of Brake Drum of Two Wheeler through Approach of Reverse Engineering by Using Ansys Software", IOSR-JMCE Volume 12, Issue 4 (July-Aug. 2015).

[8] Drum brakes were designed and analysed by Dvsrbm Subramanyam and L. Sravani for the International Journal of Research in Advanced Engineering Technology, Volume 6, Issue 1 MAY 2017.