A

Project Report Submitted

“HYDRAULIC BRAKING SYSTEM”
In a Partial
Fulfilment for the
award of the
Degree of Bachelor of Technology
In the Department of Aeronautical Engineering

Submitted To: Submitted by:

Name: Mr. Vikram Kapoor Darshan L. (1864)
Designation: Assistant Professor Nayan Kute (1863)
(Mechanical Engineering Sonu Kumar (1817)
Department) Falguni Sinha (1839)
Gouranga Samanta (1880)

School of Aeronautics (Neemrana)

I-04, RIICO Industrial Area, Distt. Alwar, Rajasthan
Affiliated to Bikaner Technical University
March 2023
 CANDIDATE’S DECLARATION

We hereby declare that the work, which is being presented in the

semester project, entitled “HYDRAULIC BRAKING SYSTEM”
in partial fulfilment of the award of the “Bachelor of Technology”
with specialization in aeronautics and submitted to the department
of aeronautical, School of Aeronautics (Neemrana), affiliated to
Bikaner university is a record of our investigation carried under
the guidance of Mr. Vikram Kapoor (Asst. Professor), School of
Aeronautics (Neemrana).

Mr. Vikram Kapoor Name: Darshan L. (1864)

Assistant Professor Nayan Kute (1863)
(Mechanical Engineering Sonu Kumar (1817)
Department) Falguni Sinha (1839)
Gouranga Samanta (1880)

CERTIFICATE
This is to certify that Darshan L., Nayan Kute, Sonu Kumar,
Falguni Sinha, and Gouranga Samanta of Third semester, B.Tech.
(Aeronautical) 2021-2025 have presented a semester project titled
“HYDRAULIC BRAKING SYSTEM” in partial fulfilment for
the award of the degree of Bachelor of Technology under Bikaner
Technical University, Bikaner.

DATE: 28th March, 2023

Mr. Vikram Kapoor

(Assistant Professor)
(Mechanical engineering
Department)

ACKNOWLEDGEMENT
We would like to express our sincere gratitude to our project
guide Mr. Vikram Kapoor for his guidance and support in this
endeavour, we also want to thank him for his great supervision.
He has been a tremendous source of encouragement and immense
support throughout our course. This project would not have been
in its present form without continuous guidance and inspiration.

Regarding omissions if any, we express our sincere apology and

take all responsibility.
Darshan L
Nayan Kute
Sonu Kumar
Falguni Sinha
Gouranga Samanta

CONTENTS
Serial No. Topic Page
No.
1. Candidate’s Declaration 1
2. Certificate 2
3. Acknowledgment 3
4. List of Figures iii
5. Abstract iv
6. Chapter 1. Introduction 4
1.1. Overview
7. 1.2 Literature review 5&6
8. 1.3 What is a hydraulic 7
Braking system?
9. 1.4 Principle of 8
hydraulic braking system
10. 1.5 Types and construction details 9&10
11. 1.6 Methodology 11
12. 1.7 Working of the master cylinder 12
of hydraulic brakes
13. Chapter 2. Construction of Hydraulic 13
braking System
14. Chapter 3. Specifications of Hydraulic 14
Brakes
15. Chapter 4. Advantages of Hydraulic 15
braking system
16. Chapter 5. Disadvantages of Hydraulic 16
Braking system
17. Chapter 6. Method of bleeding of hydraulic 17&18
brakes
18. Chapter 7. Diagram of a hydraulic braking 19
system in CATIA
19. Chapter 8. Working of hydraulic disc 20
brakes
20. Chapter 9. Applications 21
21. Chapter 10. Why liquid is used instead of 22
gas?
22. Chapter 11. Hydraulic Braking system 23,24&
working 25
23. Chapter 12. Picture of the model 26
24. Chapter 13. Conclusions 27
25. Chapter 14. References 28

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LIST OF FIGURES

Serial Figures Page

No. No.
1. Fig(a). Picture of a hydraulic braking system 4

2. Fig(b). Formula of Pascal’s Law 8

3. Fig(c). Picture of drum brakes 9

4. Fig(d). Picture of a disc brake 10

5. Fig(e). Construction of a hydraulic braking system 11

6. Fig(f). Hydraulic Braking System 12

7. Fig(g). Pressure Bleeding 17

8. Fig(h). Manual bleeding 17

9. Fig(i). Diagram of a hydraulic braking system in 19

CATIA
10. Fig(j). Hydraulic disc brake 23

11. Fig(k). Hydraulic drum brake 25

12. Fig(l). Picture of the model 26

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ABSTRACT
The focus of this project was the development of a physical
model to show the transfer of forces from the mechanical domain
to the hydraulic domain, and round back to the mechanical
domain. To do this, a wheel was designed to be stopped untold a
brake connected hydraulically to a set of callipers and a brake
rotor. Using a motor, the wheel on the dead axle was spun and
once the wheel acquired enough 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.. Once all these calculations ensured that
the successful working of the model, it was proceeded with
construction of a physical model was constructed. The physical
model was tested during its operation and it showed that the
calculations were accurate. The final model successfully shows
the shift of mechanical force (generated when the user squeezes
the handle) to hydraulic force (on the moving of piston) to
mechanical force, which creates friction between the callipers and
the brake rotor to bring the rotating wheel to a stop.

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Chapter 1: INTRODUCTION
1.1 Overview:
A hydraulic braking system is a type of braking system hatch
compared to a mechanical braking system that utilizes the
hydraulic fluid to transmit the brake pedal or brake lever force
towards the final drum shoes or caliperliper so that one can
achieve braking. In this type of braking system, the mechanical
force applied by the driver on the brake pedal is changed into
hydraulic pressure by a device known as master cylinder and then
the obtained hydraulic pressure is sent to the final drum or disc
caliper in order to enable the deacceleration the vehicle. Brake
fluid is used in hthe ydraulic brake mechanism. Glycol is used to
transfer pressure fthe rom controlling system to brake apply
system.

Fig(a). Picture of a hydraulic braking system

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1.2 Literature Review:

Brakes and tires are two essential components of the automation
system in a car. Meanwhile, a large portion of safety factors are
focused on the selection of the most efficient brake system along
with the most durable and fit tires. That is why since the early
times in the history of car manufacturing the form and
functionality of both brake systems and tires have been in
continual development. For brake systems, mechanical drum
brake was the earliest brake form that was invented in 1902 by
Louis Renault, the French car manufacturer .Meanwhile, the
concept of brake system was initiated by Gottlieb Daimler who
devised a drum with an anchoring cable to the vehicle's body is
useful for stopping the car .Then, the internal shoe brake was
invented and used widely then it was abandoned by the invention
of hydraulic brakes in 1920s to avoid the problem of shoe brake
that was susceptible to many factors like temperature. In the
middle of the 20th century, the Disc brakes were invented to go
with the new types of vehicles that were faster ad heavier in
weight as well. However, some companies decided to make a mix
between the two systems for example the Chrysler Imperial to get
the advantages of both systems, so that we can have the new
hydraulic disc brake system. Recently, with the progress in
development, the world has the new anti-lock brake system, or
(ABS) that prevented the lock of brakes while one is driving.
Wheels were the most significant invention in the history of
humans as it enabled them to transport their objects and to travel
on carts from place to another. However, metal tires were used in
first car in history. Then metal tires were replaced by rubber filled
with air in 1905 which was the first pneumatic tire with a tread. In
1931 the synthetic rubber was introduced by the DuPont

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Company which led to increase in tire production. In 1947
tubeless tire were introduced in order to reduce costs. It helped
reduce weight and make saving of fuel. It was followed by the
invention of radial tires in the 1950s, with cords and carcass plies.
Then in 1979, the run-flat tire was developed which allowed the
enabled tires to run with puncture. With enhancements for brakes
and car drivability, the tires are now greater in size than 16 inches .

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1.3 What is a hydraulic braking system?
A hydraulic system uses liquid under pressure to transfer force,
move an object, or increase its force. The fluid pressure is known
as hydraulic pressure. Brakes that are operated using hydraulic
pressure are called hydraulic brakes.
This type of braking system transfers pressure from the
controlling mechanism to the braking mechanism using brake
fluid, usually glycol ether. The first four-wheel hydraulic brake
system for a motor car was developed and installed by Ernest
Walter Weight in 1908.

The drum type of hydraulic braking system is primarily found in

low-speed four-wheelers, while the disc type of hydraulic brakes
is used in almost all cars. In addition, some types
of motorcycles also use these brakes.

It is highly efficient braking system and self-lubrication system

hence no external lubrication is required. In this system, with less
effort, we can achieve high braking force.

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1.4 Principle of hydraulic braking system:
Hydraulic brakes are entirely dependent on the principle of
Pascal’s law. 
Pascal’s law:-  The pascal law states that “Pressure at any point in
a static fluid is equal in all directions.”

Hence such pascal’s law is used in the hydraulic braking system

to apply the brake.

Fig(b). Formula of Pascal’s Law

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1.5 Types and construction details:

The Hydraulic braking system has been classified on 2 bases
1. Based on frictional contact mechanism
(i) Drum brake also referred as internal expanding hydraulic
brakes
(ii) Disc brakes also referred as external contracting hydraulic
brakes.
2. Based on brake force distribution
(i) Single acting hydraulic brakes
(ii) Dual acting hydraulic brakes
Drum brake: -It is a brake that utilizes the friction caused by the
shoes or pads that press outwards towards a rotating cylinder-
shaped part referred to as brake drum. The term drum brake
usually refers to a brake in which shoes are pressed on the inner
surface of the drum. When shoes are pressed on the outside region
of the drum, it is commonly called a clasp brake. A pinch drum
brake refers to when the drum is pinched between two shoes,
quite like a conventional disc brake. Another type called a band
brake makes use of a flexible belt or "band" wrapping around the
outside of a drum.

Fig(c). Picture of drum brakes

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Disc brake:- makes use of the callipers to squeeze pairs of pads

against a disc or a rotor to generate friction. This action slows
down the rotation movement of a shaft, such as a vehicle axle.
The motion energy is converted into waste heat which must be
distributed. These are the most used types of brake for motor
vehicles.

Fig(d). Picture of a disc brake

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1.6 Methodology:
The friction between the pads and the rotor causes a braking
torque to be generated, which bring down slow speed. Heat
generated by this friction is released through vents and channels
in the rotor or is transferred through the pads, which are made of
special heat-tolerant substances such as Kevlar or sintered glass.
In similar fashion, in a drum brake, the fluid moves into the wheel
cylinder and presses one or two brake shoes towards the inside of
the spinning drum. This action first relieves the hydraulic pressure
on the calliper, and then applies suction to the brake piston in the
calliper assembly, moving it back into its housing and enabling
the brake pads to release the rotor.

Fig(e). Construction of a hydraulic braking system

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1.7 Working of master cylinder of hydraulic brakes:

i) Brakes applied: When the brake pedal is used, the pushrod
moves the piston towards the action of the spring force. When
sufficient pressure is built up, the rubber cap of fluid check valve
deflects and the high-pressure fluid enters the wheel cylinder
through fluid lines and operates the brake shoe against the
revolving drum.
ii) Brakes released: When the pedal is allowed to release, the
piston return towards its initial position due to the spring force
and stops the fluid check valve for a short duration to avoid entry
of any air. The fluid from the lines also comes back in the
compression chamber by lifting the check valve off its seat.

Fig(f). Hydraulic braking system

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Chapter 2. Construction of Hydraulic braking System

The constructional arrangement of hydraulic brakes consists of
various parts such as the brake pedal or level, a pulley, also
known as an actuating rod, and a piston in a master cylinder
assembly.

The master cylinder includes one or two pistons, a return spring, a

series of gaskets or O rings, and a fluid reservoir. In addition, it
also featured reinforced hydraulic lines and brake calliper
assembly. The brake calliper assembly consists of one or two
hollow aluminium pistons (called calliper pistons), a set of
thermally conductive brake pads, and a brake disc.

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Chapter 3. Specifications of Hydraulic Brakes:

The following performance specifications should be considered
when choosing a hydraulic brake:
#1 Torque Rating

It is recommended that the brake’s maximum torque rating

matches or exceeds the requirements of the application.

#2 Power

For hydraulic brakes, it is a measure of their maximum power.

#3 Speed

This specification applies only to rotary brakes and represents the

maximum rotary speed.

#4 Maximum Pressure

For hydraulic brakes, it is the maximum pressure.

#5 Shaft Configuration

Depending on the application, the brake may be mounted in-line,

parallel, or at an angle.

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Chapter 4. Advantages of Hydraulic braking system:

1. Hydraulic disc brakes provide more braking power.
 2. These brakes have a large contact area, which supports heat
dissipation.
3. Hydraulic brakes rarely fail, making them reliable at high
speeds.
4. These brakes work better in wet and muddy conditions than
mechanical brakes.
5. Since it is a hydraulic system, it includes power, accuracy,
efficiency, and ease of maintenance.
6. Equal braking effort to all the four wheels
7. Less rate of wear (due to absence of joints compared to
mechanical brakes)
8. Force multiplication (or divisions) very easily just by
changing the size of one piston and cylinder relative to
other.

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Chapter 5. Dis-advantages of Hydraulic Braking system:

1. They have a relatively high price compared to mechanical
brakes.
2. The brake fluid used in the braking system must be
compatible with the brake material.
3. Braking fluid leakage may occur, which will result in brake
failure.
4. Unlike mechanical brakes, hydraulic brakes require more
maintenance and construction.
5. Even slight leakage of air into the breaking system makes it
useless.
6. The brake shoes are liable to get ruined if the brake fluid
leaks out

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Chapter 6. Method of bleeding of hydraulic brakes:
A) Pressure Bleeding: The master cylinder is supplied
pressurized brake fluid from the pressure bleeder. the
pressure force air and brake fluid out of the bleeder screw
on the opening of the bleeder screw. With the aid of
pressure bleeder, one can bleed the hydraulic system
without requiring helper.

Fig(g).Pressure bleeding

B) Manual Bleeding: Two service technicians are required for

the operation of manual bleeding process. One technician
works towards opening the bleeder and the other operator
depresses the pedal, to force out air and brake fluid from the
bleeder screw.

Fig(h). Manual bleeding

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C) Gravity bleeding : It is the method of bleeding that
utilizes the earth’s gravity to bleed air from the hydraulic
system. It requires no application of external force is to the
brake fluid.

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Chapter 7. Diagram of a hydraulic braking system in
CATIA:

Fig(i). Hydraulic disc brake in CATIA

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Chapter 8. Working of hydraulic disc brakes:
Let’s see the Hydraulic Braking system working in stepwise:-

1) When the driver presses the brake pedal, the piston presses the
oil inside the master cylinder.

2) Oil flows from the master cylinder to cylinder 2 through a

pipeline.

3) Now, Oil enters inside the cylinder 2. Hence both piston

expands due to oil pressure.

4) Due to piston movement, brake shoes expand inside the brake

drum.

Therefore, due to friction between shoes & brake drum, the wheel
stops.

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Chapter 9. Applications:
1. These types of brakes are primarily used in cars and other
automobile applications.
2. Drum-type hydraulic brakes are used in some low-speed
four-wheelers like trolly vehicles.
3. Disc-type hydraulic brakes are used in almost all cars and
also be used in bikes.
4. Single-acting hydraulic brakes are used as front brakes in
some types of bikes.
5. Dual-acting hydraulic brakes are used in almost all vehicles.
6. In addition to automotive applications, these brakes can also
be seen in oil field operations.
7. Additionally, it is also used in power generation stations
such as wind turbines.

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Chapter 10. Why liquid is used instead of gas?
a) At all the points in the fluid the pressure will remain constant
which is at rest and fluid exerts equal pressure in all directions
with respect to the pressure exerted on it.
b) Thus, the hydraulic fluid is used to operate the brakes in a car.
c) Liquids are used in hydraulic systems because liquids are
incompressible.
d) If we use a gas, on increasing the pressure, the gas will be
compressed into a smaller volume due to which there will be
no transmission of force or motion.
e) The particles in a liquid (the brake oil) can move freely
without being compressed much and hence transmit the
pressure applied on brake pedal to the brake drum (on
moving wheel) efficiently.
f) The incompressibility of liquids allows that a small change
in pressure caused by the driver's foot is equally distributed
over the whole liquid. The brakes are surrounded by a far
greater area of liquid than the extension of the brake pedal.
Hence, a small force applied by the driver's foot will result
in a far greater force applied on the brakes.

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Chapter 11. Hydraulic Braking system working
The working of the hydraulic braking system is straightforward.
To understand the function of these brakes, let’s consider disc
brake and drum brake. In both types, initial work is similar, but
performance styles differ.

When using disc brakes, the brake calipers and discs apply the
brake, whereas when using drum brakes, the brake shoes and
drums apply the brake. Let us understand the working of these
two brakes in detail.

Fig(j). Hydraulic Disc Brake

Hydraulic Disc Brakes: Disc hydraulic brakes work by applying

pressure or force on the brake pedal. This action generates
compressive force, which causes the brake fluid to be compressed
into the master cylinder through a piston-cylinder arrangement

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In the system, the hydraulic fluid creates pressure in the hydraulic
lines and transfers this pressure to the disc brake calipers,
between which the disc is mounted. Both the brake calipers
consist of a piston arrangement. Brake pads are mounted on
pistons.

When the brake pedal is pressed, both pistons start moving

towards the disc. Finally, the brake caliper compresses the disc,
and the brake is applied, which means that the moving parts cease
to move. Upon releasing the brake pedal, the hydraulic pressure in
the lines drops, and the pistons in the calipers move outward, thus
releasing the brakes.

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 Fig(k).Hydraulic drum brake

Hydraulic Drum Brakes: In the beginning, the working of the

drum brake and disc brake is the same. The main difference lies
in the performance of these brake types. Whenever the driver
applies the brakes, the piston will be pushed inside the master
cylinder by the connecting rod that connects the pedal to the
piston.

When this fluid starts moving, it causes compression of the brake

fluid inside the master cylinder. Due to this, it expands and
converts mechanical energy into hydraulic pressure. In the end, it
converts the kinetic energy of the vehicle into heat energy, and
the vehicle completely stops moving.

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Chapter 12. Picture of the model:

Fig(l). Picture of the model

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Chapter 13. Conclusions:
The conventional braking system has ability to develope
maximum <80% of the braking effort that required to stop the
vehicle in desired distance. While, the braking system is designed
to develop 100% braking effort to stop the car in desired distance
corresponding to the speed. The lacking of the braking effort
development due to the slow response of the driver Chances of
brake failure are reduced in the hydraulic braking system
compared to the mechanical types, because of the direct
connection between the actuator (brake pedal or lever) and the
brake disc or drum. The hydraulic braking system is very easy to
fix due to its less complexity compared to mechanical brakes. The
Hydraulic Brake System is being more popular due to its
advantages and easy to use. The modern automobiles like bikes,
cars, and heavy vehicles are adapting this technology. The fluids
used in this system can vary according to its application because
the heavy vehicles require more effort or pressure to push the
brakes and stop the rotary wheel. Few of its applications can be
seen in mopeds nowadays.

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Chapter 14. References :
E- BOOKS
 Automobile Engineering, Vol. II., p. 183. American
Technical Society, Chicago, 1919
 Loughhead, Malcolm, "Braking apparatus," U.S. Patent no.
1,249,143 (filed: 1917January 22 ; issued: 1917 December
4).
 Dr A.K.SINGH Automobile Eng, Vayu Publication
REFERENCE LINKS
 https://dokumen.tips/documents/project-report-on-hydraulic-
disc-brakes.html?page=54
 https://www.theengineerspost.com/hydraulic-braking-
system/
 https://www.academia.edu/30931948/
A_PROJECT_ON_STUDY_AND_DESIGN_OF_HYDRA
ULIC_BRAKING_SYSTEM_A_Minor_Project_and_Semin
ar_report_submitted_at
 https://www.clippard.com/cms/sites/default/files/
wiki_images/pascals-law.jpg
 https://mechcontent.com/hydraulic-braking-system/
 https://www.jetir.org/papers/JETIR2206426.pdf