Design and Fabrication of Hydraulic Braking System for Formula Student Vehicle

Roop Lal Rana; Kartik Dahiya; Abhishek Bhardwaj; Sahil Shah

doi:https://doi.org/10.51976/ijari.922112

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Design and Fabrication of Hydraulic Braking System for Formula Student Vehicle

Roop Lal Rana, Kartik Dahiya, Abhishek Bhardwaj, Sahil Shah

Vol 9 , Issue 2 , April - June 2021 | Pages: 76-83 | Research Paper

https://doi.org/10.51976/ijari.922112

Received: January 15, 2021 | Revised: May 19, 2021 | Accepted: June 05, 2021 | Published Online: June 15, 2021

Author Details ( * ) denotes Corresponding author

1. * Roop Lal Rana, Department of Mechanical Engineering, Delhi Technological University, Delhi, India (rooplalrana@dce.ac.in)

2. Kartik Dahiya, Department of Mechanical Engineering, Delhi Technological University, Delhi, India (kartikdahiya_2k17pe26@dtu.ac.in)

3. Abhishek Bhardwaj, Department of Mechanical Engineering, Delhi Technological University, Delhi, India (abhishekbhardwaj_2k17pe03@dtu.ac.in)

4. Sahil Shah, Department of Mechanical Engineering, Delhi Technological University, Delhi, India (sahilshah_2k17pe47@dtu.ac.in)

Present paper encompasses design of a hydraulic braking system with a pedal box. The system is designed for a single person formula student vehicle weighing 250kg. The objective of the system is to convert the kinetic energy into thermal energy allowing the vehicle to decelerate safely. The paper is divided into various categories namely; calculation and evaluation of the hydraulic system in order to select calipers and master cylinders, the design of the pedal box, the design of the rotors and manufacturing the components. After the calculation it was found that the braking torque required for the vehicle to stop after considering load transfer is 150 Nm and 130Nm for front and rear tires respectively. Willwood master cylinder was selected which provided hydraulic pressure of 4.89Mpa to the front brake lines and 4.17Mpa to the rear brake lines. Vespa calipers were selected with two pistons which provided braking force of 8022.32 N at the front calipers and 6559.332 N at the rear calipers. Pedal box was designed consisting a brake pedal and two master cylinder mountings. It is designed for minimum mass and maximum strength.

Keywords

Automobile braking; Formula student; Heat transfer; Hydraulic braking

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