A Project Report On Fabrication of Hydraulic Disc Brake: Under The Guidance of H.O.D. (Mechanical Department)

A
Project Report
On
FABRICATION OF HYDRAULIC DISC BRAKE
Submitted in the partial fulfillment of the requirement of degree in

BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING
Submitted By
MD NADIM AKHTAR
(1225640020)
MOHD. AZAM
(1225640025)
B.Tech. IV-Year
MR. AZEEM AHMAD Under the Guidance of

H.O.D. (Mechanical Department) MR. RINTU SINGH
D.N.S COLLEGE OF ENGINEERING & TECHNOLOGY
NH- 24, DIDAULLI, AMROHA
SESSION: 2016-2017
ACKNOWLEDGEMENT
I take this opportunity to express deep gratitude to the Director of DNS COLLEGE OF
ENGINEERING AND TECHNOLOGY, Amroha, J.P Nagar. I express my deep gratitude
to the H.O.D Er .Rintu Singh Of Mechanical Engineering.
It is indeed a great pleasure and a matter of immense satisfaction to express my guidance,
useful suggestions and adlibbing inspiration throughout the preparation of project. Their
guidance has helped me to gain vast amount of knowledge.
At last but not the least I also express my sincere thanks to my parents, family and friends
for providing their continued moral support.
MD NADIM AKHTAR - 1225640020

MOHAMMAD AZAM - 1225640025
B.Tech - ivth Year
CERTIFICATE
This is to certify that the project report entitled FABRICATION OF HYDRAULIC
DISC BRAKE is submitted by MD NADIM AKHTAR, MOHAMMAD AZAM under
our guidance and supervision in partial fulfilment for award of degree of Bachelor of
Technology they have completed the project successfully and I wish him them every success
in their career.
(Project Guide) (Head Of Department)
Table of Contents
Abstract
...................................................................................................................................
Introduction........................................................................................................................
Disc Brake. ...........................................................................................................................
Background.......................................................................................................................8-
12
Disc....................................................................................................................................13-
14
Racing .....................................................................................................................................
15
Warping............................................................................................................................16-
17
Cranking................................................................................................................................1
8
Calipar....................................................................................................................................1
Piston and cylinder..........................................................................................................20
Brake pads..........................................................................................................................21-
23
Brake dust...........................................................................................................................24-
25
Design calculation............................................................................................................26-
31
Fabrication and assembly................................................................................................32-
33
Analysis
.............................................................................................................................34-36
Methodology
.......................................................................................................................37-39
Manufacturing...................................................................................................................40-
47
Appendix..................................................................................................................................
48
Bill of material...................................................................................................................49-
52
Notes &
references.................................................................................................................53
Table of Figures
Figure 1: Example of the Lever Brake................................................................................ 8
Figure 3: Example of a Disk Brake..................................................................................... 9
Figure 4: Brake Rotors........................................................................................................10
Figure 5: Brake Pads...........................................................................................................11
Figure 6: SolidWorks simulation of Deformation............................................................ 12
Figure 7: SolidWorks simulation of von Mises Stress......................................................26
Figure 8: Testing to Find the Mechanical Advantage of the Hydraulic Brake.................27
Figure 9: Second Revision of the Assembly.....................................................................28
Figure 10: Third and Final Revision of the Assembly.....................................................29
Figure 11: Flywheel Operation 1 and 2 in Esprit..............................................................31

Figure 12: Cutting the Shaft and Using a Tail-Stock........................................................35
Figure 13: Support structure in Esprit...............................................................................36
Abstract
The objective of this project was to create a physical model to demonstrate the transfer of
forces from the mechanical domain to the hydraulic domain, and back to the mechanical
domain. To do this, a spinning wheel was designed to be stopped using a hand brake
connected hydraulically to a set of calipers and a brake rotor. A wheel on a dead axle was
spun up via a motor and once the wheel was at speed, mechanical force was applied to the
hand brake to bring the wheel to a stop. Calculations for the model were made to
determine flexure, stress concentrations, natural frequency and the mechanical advantage
of the braking system. The calculations showed that under normal operating conditions,
the whole assembly will not have any noticeable flexure, the stress concentrations in the
axle will not lead to catastrophic failure, the natural frequency of the rotating wheel on a
simply supported axle is far above that of the operating frequency, and the hydraulic brake
has ample mechanical advantage to safely bring the wheel to a stop. Once all these
calculations ensured that the model would not fail during operation, a physical model was
constructed. Testing and operation of the physical model showed that the calculations were
accurate.

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A

Submitted in the partial fulfillment of the requirement of degree in

MR. AZEEM AHMAD Under the Guidance of

ENGINEERING AND TECHNOLOGY, Amroha, J.P Nagar. I express my deep gratitude

to the H.O.D Er .Rintu Singh Of Mechanical Engineering.

It is indeed a great pleasure and a matter of immense satisfaction to express my guidance,

guidance has helped me to gain vast amount of knowledge.

for providing their continued moral support.

MD NADIM AKHTAR - 1225640020

DISC BRAKE is submitted by MD NADIM AKHTAR, MOHAMMAD AZAM under

Disc Brake. ...........................................................................................................................

Piston and cylinder..........................................................................................................20

Fabrication and assembly................................................................................................32-

Figure 1: Example of the Lever Brake................................................................................ 8

Figure 3: Example of a Disk Brake..................................................................................... 9

Figure 4: Brake Rotors........................................................................................................10

Figure 5: Brake Pads...........................................................................................................11

Figure 6: SolidWorks simulation of Deformation............................................................ 12

Figure 7: SolidWorks simulation of von Mises Stress......................................................26

Figure 8: Testing to Find the Mechanical Advantage of the Hydraulic Brake.................27

Figure 9: Second Revision of the Assembly.....................................................................28

Figure 10: Third and Final Revision of the Assembly.....................................................29

Figure 11: Flywheel Operation 1 and 2 in Esprit..............................................................31

Figure 13: Support structure in Esprit...............................................................................36

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