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.

1. Organization of Dissertation

Table 1: Organization of Dissertation

2. 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.

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.