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INTERNATIONAL JOURNAL OF ADVANCED
PRODUCTION AND INDUSTRIAL ENGINEERING
IJAPIE-2020-01-143, Vol 5 (1), 25-32
https://doi.org/10.35121/ijapie202001143
IJAPIE
Connecting
Science & Technology
with Management.
A Journal for all
Products & Processes.
| IJAPIE | ISSN: 2455–8419 | www.ijapie.org | Vol. 5 | Issue. 1 | 2020 | 25 |
Designing and Analyzing the Brake Master Cylinder for an ATV vehicle
Shubham Upadhyaya1, Divyam Raj1, Kaushal Gupta1, Rakesh Chander Saini2,*, Ramakant
Rana2, Roop Lal3
(1Student, Mechanical and Automation Engineering Department, Maharaja Agrasen Institute of Technology,
Delhi India, 2Assistant Professor, Mechanical and Automation Engineering Department, Maharaja Agrasen
Institute of Technology, Delhi India, 3Assistant Professor, Mechanical Engineering Department, Delhi
Technological University, Delhi India)
*Email: rakeshchandersaini@gmail.com
ABSTRACT: Braking system is a means of converting momentum into heat energy by creating friction in the
wheel brakes. The braking system which works with the help of hydraulic principles is known as hydraulic
braking systems. The most frequently used system operates hydraulically, by pressure applied through a liquid.
These are the foot operated brakes that the driver normally uses to slow or stop the car. Our special interest in
hydraulics is related to the actions in automotive systems that result from pressure applied to a liquid. This is
called hydraulic pressure. Since liquid is not compressible, it can transmit motion. A typical braking system
includes two basic parts. These are the master cylinder with brake pedal and the wheel brake mechanism. The
other parts are the connecting tubing, or brake lines, and the supporting arrangements. The present paper is
about designing of Twin master cylinder system for and all-terrain vehicle and doing a feasibility study of its
strength using ANSYS. Our work is focused on reducing weight which is one of the factors to increase the
efficiency. Reduction in weight and space, due to its compactness. The twin Master cylinder system is a great
advancement in braking system for an ATV. 3-D CAD modeling is done using SOLIDWORKS 2017, whereas the
analysis of its strength is done using ANSYS.
Keywords: Hydraulic System, Brake, Master Cylinder, Analysis, Design, Twin Master Cylinder
I. INTRODUCTON
Master cylinder is a component of hydraulic braking system and it is just a simple piston inside a cylinder.
Master cylinder is the key element of braking system which initiates and controls the braking action. A reservoir
is attached to the master cylinder to store brake fluid. A master cylinder having a reservoir and a cylinder
formed from a single piece of molded material. Master cylinder is a component of hydraulic braking system and
it is just a simple piston inside a cylinder. Master cylinder is the key element of braking system which initiates
and controls the braking action. A reservoir is attached to the master cylinder to store brake fluid. A master
cylinder having a reservoir and a cylinder formed from a single piece of molded material [1-3]. The master
cylinder displaces hydraulic pressure to the rest of the brake system. It holds the most important fluid in your
car, the brake fluid. It actually controls two separate subsystems which are jointly activated by the brake pedal.
This is done so that in case a major leak occurs in one system, the other will still function. The two systems may
be supplied by separate fluid reservoirs, or they may be supplied by a common reservoir. Some brake
subsystems are divided front/rear and some are diagonally separated. When you press the brake pedal, a push
rod connected to the pedal moves the "primary piston" forward inside the master cylinder. The primary piston
activates one of the two subsystems [4-6]. The hydraulic pressure created, and the force of the primary piston
Shubham Upadhyaya et al.,
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| IJAPIE | ISSN: 2455–8419 | www.ijapie.org | Vol. 5 | Issue. 1 | 2020 | 26 |
spring, moves the secondary piston forward. When the forward movement of the pistons causes their primary
cups to cover the bypass holes, hydraulic pressure builds up and is transmitted to the wheel cylinders. When the
brake pedal retracts, the pistons allow fluid from the reservoir to refill the chamber if needed. Electronic sensors
within the master cylinder are used to monitor the level of the fluid in the reservoirs, and to alert the driver if a
pressure imbalance develops between the two systems. If the brake light comes on, the fluid level in the
reservoir(s) should be checked. If the level is low, more fluid should be added, and the leak should be found and
repaired as soon as possible [7-11].
The master cylinder displaces hydraulic pressure to the rest of the brake system. It holds the most important
fluid in your car, the brake fluid [12]. It actually controls two separate subsystems which are jointly activated by
the brake pedal. This is done so that in case a major leak occurs in one system, the other will still function [13-
15]. The master cylinder displaces hydraulic pressure to the rest of the brake system. It holds the most important
fluid in your car, the brake fluid. It actually controls two separate subsystems which are jointly activated by the
brake pedal. This is done so that in case a major leak occurs in one system, the other will still function [16-19].
The two systems may be supplied by separate fluid reservoirs, or they may be supplied by a common reservoir.
Some brake subsystems are divided front/rear and some are diagonally separated. When you press the brake
pedal, a push rod connected to the pedal moves the "primary piston" forward inside the master cylinder. The
primary piston activates one of the two subsystems [20-22]. The hydraulic pressure created, and the force of the
primary piston spring, moves the secondary piston forward. When the forward movement of the pistons causes
their primary cups to cover the bypass holes, hydraulic pressure builds up and is transmitted to the wheel
cylinders [23-26].
II. DESIGN CONSIDERATIONS OF MASTER CYLINDER
The basic information about brake system and its master cylinder, function, purpose, working principle,
different shape and size of master cylinder, failure considerations has been taken from automotive brake system.
The work done by brake system parts manufacturers tells that cost mold brake master cylinder made of cast iron
was used universally in all the old car and light trucks and after that there has been increased research done on
improving the mileage of the vehicle by reducing the weight. The research made a way to concentrate on
reducing the weight of brake master cylinder by changing the materials [27, 28].
The manufacturers came up with new idea of composite master cylinder having integral body made of
aluminum and reservoir made of plastic material and thus reducing the weight when compare to cost mold
master cylinder made of cast iron. Those manufacturers are concentrating on reducing weight of master cylinder
by changing the material and by changing the type of manufacture [29]. This information gives basic steps for
this project in taking reduction of weight further and considering plastic material to design brake master
cylinder. The second edition of brake design and safety gives basic design considerations to design safer brakes
and its components. The standard of quality of brake technology as changed over the last two decades. The new
design can only be achieved through proper research, through the use of sound engineering concepts and testing
the results of small design changes. The information provided by the author has helped in considering
engineering design concepts, safety considerations, material selection, guides, standards and practices for the
project [30].
III. Experiment Calculations
Important Parameters:
Pedal Force applied by driver (FP) = 250 N Pedal Leverage = 4.5
Wheel Torque (Tc) = 161 Nm
Brake caliper piston diameter (Dc) = 32 mm Maximum piston travel of caliper (Lc) = 1.5mm Radius of
disc (R) = 190 mm
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| IJAPIE | ISSN: 2455–8419 | www.ijapie.org | Vol. 5 | Issue. 1 | 2020 | 27 |
Assumptions:
Deceleration = 0.8g
Coefficient of friction between tire and ground = 0.78 Coefficient of friction between pads and
Disc = 0.35 Dynamic weight transfer = 75.66 kg
Piston Diameter Calculations:
FM = Force on master cylinder
Fm = Fp x l
FC = Force on caliper
Fc = Tc/R
Ac = Area of caliper piston
A = (π /4) x Dc2
P = Pressure in the system
P = Fc/Ac
Am = Area of piston
Am = Fm/P
M = Master cylinder bore diameter
Dm = √ (Am x 4/ π)
Stroke Length Calculations:
V = Volume displaced by caliper piston
V = π x Dc2 x Lc / 4
Lm = Stroke length of master cylinder
Lm = 4 x V / π x Dm2
IV. CAD MODELING
Finite Element Analysis is a practical application of Finite Element Method (FEM). FEM is a numerical
technique for finding approximate solutions to boundary value problems for partial differential equations. It uses
subdivision of a whole problem domain into simpler parts, called finite elements, and variational methods from
the calculus of variations to solve the problem by minimizing an associated error function. Analogous to the
idea that connecting many tiny straight lines can approximate a larger circle, FEM encompasses methods for
connecting many simple element equations over many small subdomains, named finite elements, to approximate
a more complex equation over a larger domain.
A simple structural analysis was performed as the first step to see if components were structurally strong. If a
component failed with the loadings, then no need to continue stress or fatigue analysis since the component is
Shubham Upadhyaya et al.,
International Journal of Advanced Production and Industrial Engineering
| IJAPIE | ISSN: 2455–8419 | www.ijapie.org | Vol. 5 | Issue. 1 | 2020 | 28 |
not strong enough to be used. The analysis of the various components of the master cylinder was done in
ANSYS 16.0 WORKBENCH for meshing as well as solving.
Meshing of all the parts was done in ANSYS. The mesh is generated by using tetrahedron elements of 1 mm
size. Mesh quality is further improved by using proximity and curvature function. This improves mesh density
where curvature is small or edges are closed in proximity.
Material used is Al 6061 with Syt=350 Mpa,
Poisson’s ratio=0.33 and Density=2700 kg/m3.
The boundary conditions applied are pressure generated in cylinder casing and the axial force applied through
the push rod. The casing is fixed at the mounting points. For the braking system consider which is for an ATV
the applied braking force is assumed to be 350 N. The force is magnify by the leverage of 4.5 provided by the
pedal assembly and 1575 N force is applied by the push rod. Also the maximum pressure generated in system is
applied on inner surfaces of casing.
The results of maximum stress and deformation shows that the master cylinder is safe for designed shell and
mounting thickness.
Maximum Stress (Cylinder casing) = 177.6 Mpa
Maximum Deformation (Cylinder casing) = 0.02 mm
Maximum Stress (Piston) = 138.52 Mpa
Maximum Deformation (Piston) = 0.0108 mm
V. ANALYSIS
Figure 1: FEM Design analysis step 1
Shubham Upadhyaya et al.,
International Journal of Advanced Production and Industrial Engineering
| IJAPIE | ISSN: 2455–8419 | www.ijapie.org | Vol. 5 | Issue. 1 | 2020 | 29 |
Figure 2: FEM Design analysis step 2
Figure 3: FEM Design analysis step 3
Figure 4: FEM Design analysis step 4
Shubham Upadhyaya et al.,
International Journal of Advanced Production and Industrial Engineering
| IJAPIE | ISSN: 2455–8419 | www.ijapie.org | Vol. 5 | Issue. 1 | 2020 | 30 |
VI. CONCLUSIONS
Vehicle dynamics have been carefully studied. It included design of rear and front suspension, load transfer
calculations, design of springs, selection of bearings and analysis in ANSYS Workbench. The purpose of the
paper is not only the designing of suspension and steering of hybrid tricycle but also to provide in depth study to
increase the performance of the vehicle in terms of vehicle dynamics. Design features have been proven
effective in terms of vehicle dynamics and the results from FEA indicate the real track performance is quite safe.
VII. ACKNOWLEDGEMENT
Authors extend their regards to the Centre for Advanced Production and Industrial Engineering Research
(CAPIER) of Delhi Technological University, New Delhi, India, for providing the layout for this research.
Authors would also like to acknowledge and give special thanks to the support of “Metrology Lab” and
“Research and Development Lab” of Maharaja Agrasen Institute of Technology, New Delhi, India, for
providing the facilities for the completion of this work.
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