A PROJECT REPORT

ON STUDY OF BRAKES

SUBMITTED TO :A.V.SHITOLE SR. TRAINING OFFICER COLLEGE

PREPARED BY:ANSHUL SIKCHI S.D.BANSAL

FORCE MOTORS LTD. TECHNOLOGY, INDORE

OF

ACKNOWLEDGEMENT
I have taken efforts in this project. However, it would not have been possible without the kind support and help of many individuals and organizations. I would like to extend my sincere thanks to all of them. I am highly indebted to MR. A GOLKONDA(SENIOR MANAGER QUALITY CONTROL-ASSEMBLY) for their guidance and constant supervision as well as for providing necessary information regarding the project & also for their support in completing the project. I would like to express my gratitude towards FORCE MOTORS FAMILY for their kind cooperation and encouragement which help me in completion of this project. I would like to express my special gratitude and thanks to industry persons for giving me such attention and time. My thanks and appreciations also go to my colleague in developing the project and people who have willingly helped me out with their abilities.

MR. A GOLKONDA

SR. MANAGER QC ASSLY.

PROFILE OF FORCE MOTORS

Force Motors (known as Bajaj Tempo Ltd. until 2005) was founded in 1957 when Mr. N. K. Firodia signed a collaboration with Vidal & Sohn Tempo Werke GmbH for phased manufacturing of the Tempo 3-Wheeler & manufacturing was started in a small plant at Goregaon, Bombay. Force Motors has historically focused on the light commercial vehicle transport segments in India with brands such as Tempo, Metador, Trax and the Traveller. It exports its complete range of products to various countries in the Middle East, Asia, Latin America and Africa. The company sells products in five segments namely Small Commercial Vehicles (SCV), Multi Utility Vehicles (MUV), Light Commercial Vehicles (LCV), Tractors and Heavy Commercial Vehicles (HCV). HCVs are products under MAN Force Trucks Pvt. Ltd which is a 50:50 joint venture between MAN Nutzfahrzeuge AG of Germany and Force Motors Ltd. of India. The joint venture has a installed capacity of 24,000 trucks per annum at its state of the art plant at Pithampur, near Indore (MP), half the production is earmarked for exports through the global MAN Sales Organization. The range of products

manufactured includes Mining & Construction Tippers, Haulage Tractors and Multi Axle Trucks, from 16t GVW to 49t GCW.

Mr. Abhay N. Firodia is the Chairman & Managing Director whilst Mr. Prasan Firodia is the Managing Director. The company has approximately 7,000 employees and hopes to achieve a turnover of Rs. 1,800 crores in 2010-11. The JV reported a turnover of Rs. 368 crores in the first half of 201011 compared to Rs. 130 crores in the same period in 2009-10.

HISTORY OF FORCE MOTORS

In 1950, Mr N. K Firodia started manufacturing the Tempo 3-Wheeler in collaboration with Vidal and Sohn. In 1957, the 3 Wheeler started being manufactured from Goregaon, Mumbai. In 1964, the 4 Wheeled trucks and vans were introduced in November. The Viking vehicle was thereafter fitted with a diesel engine and the MATADOR was launched five years post that. The Motor production started with Daimler Benz with the Mercedes Benz OM 616 engine under license for fitting its own vehicles. In 1996, Computer Aided Design and Computer Aided Manufacturing facilities were introduced. A global tractor was then designed that had transmission technology from

ZF, Germany, technical assistance for engine from Austria and hydraulics technology from Bosch. Soon after, in 1999, a 35 HP version of the tractor, the OX 35 was introduced. Light Commercial Vehicles- the EXCEL range of state of the art vehicles was introduced. These LCVs could carry loads of up to 4 tonnes. These vehicles with their ergonomics and aggregates represented the latest generation of LCVs that India had.

FUTURE PLANS
Force aims to be the market leader in Light Commercial Vehicles (LCV). Force Motors is looking to re-engineer its product line to meet the norms and emission standards along with getting into newer segments and expanding dealership network. Force is expected to sell 4000 SUVs in 2011. In 2011, it plans to come up with two-three-new models of SUVS priced at Rs. 10-12 lakh and running on a Mercedes Benz Engine. The car is Euro IV compliant and will be Euro V compliant too. 70-80% of its parts will be produced locally in India. The company also plans to have a personalized vehicle division which will add 50 dealerships as a mix of existing and new dealers who will set up workshops and sales outlet for PVs. Along with the SUV, light commercial vehicles and dealerships Force also plans to launch a passenger van which will seat 8 or 9 people. This van is targeted at families and will be launched at a price tag of under 10 lakhs, cheaper than the Force SUV. It will come in a Diesel Engine which is the OM Series from Daimler.

STUDY OF BRAKES
A brake is a mechanical device which stops/retards motion. Most commonly brakes use friction to convert kinetic energy into heat, though other methods of energy conversion may be employed. Friction brakes on automobiles store braking heat in the drum brake or disc brake while braking then conduct it to the air gradually. When traveling downhill some vehicles can use their engines to brake. When the brake pedal is pushed a piston pushes the pad towards the brake disc which slows the wheel down. On the brake drum it is similar as the cylinder pushes the brake shoes towards the drum which also slows the wheel down.

DISC BRAKES
Most modern cars have disc brakes on the front wheels, and some have disc brakes on all four wheels. This is the part of the brake system that does the actual work of stopping the car. The most common type of disc brake on modern cars is the single piston floating caliper. In this article, we will learn all about this type of disc brake design.

Disc Brake Basics Here is the location of the disc brakes in a car:

The main components of a disc brake are: The brake pads The caliper, which contains a piston The rotor, which is mounted to the hub

Parts of a disc brake The disc brake is a lot like the brakes on a bicycle. Bicycle brakes have a caliper, which squeezes the brake pads against the wheel. In a disc brake, the brake pads squeeze the rotor instead of the wheel, and the force is transmitted hydraulically instead of through a cable. Friction between the pads and the disc slows the disc down.

A moving car has a certain amount of kinetic energy, and the brakes have to remove this energy from the car in order to stop it. How do the brakes do this? Each time you stop your car, your brakes convert the kinetic energy to heat generated by the friction between the pads and the disc. Most car disc brakes are vented.

Disc brake vents

Vented disc brakes have a set of vanes, between the two sides of the disc,that pumps air through the disc to provide cooling.

EMERGENCY BRAKES
In cars with disc brakes on all four wheels, an emergency brake has to be actuated by a separate mechanism than the primary brakes in case of a total primary brake failure. Most cars use a cable to actuate the emergency brake.

Disc brake with parking brake Some cars with four-wheel disc brakes have a separate drum brake integrated into the hub of the rear wheels. This drum brake is only for the emergency brake system, and it is actuated only by the cable; it has no hydraulics. Other cars have a lever that turns a screw, or actuates a cam, which presses the piston of the disc brake.

Servicing Your Brakes

The most common type of service required for brakes is changing the pads. Disc brake pads usually have a piece of metal on them called a wear indicator.

Disc brake pad

When enough of the friction material is worn away, the wear indicator will contact the disc and make a

squealing sound. This means it is time for new brake pads. There is also an inspection opening in the caliper so you can see how much friction material is left on your brake pads.

Sometimes, deep scores get worn into brake rotors. This can happen if a worn-out brake pad is left on the car for too long. Brake rotors can also warp; that is, lose their flatness. If this happens, the brakes may shudder or vibrate when you stop. Both of these problems can sometimes be fixed by refinishing (also called turning or machining) the rotors. Some material is removed from both sides of the rotors to restore the flat, smooth surface.

Disc Brake Diagram Now let's put the parts together to see how disc brakes work as a whole. This diagram shows the

basic parts that

To increase safety, most modern car brake systems are broken into two circuits, with two wheels on each circuit. If a fluid leak occurs in one circuit, only two of the wheels will lose their brakes and your car will still be able to stop when you press the brake pedal.

The master cylinder supplies pressure to both circuits of the car. It is a remarkable device that uses two pistons in the same cylinder in a way that makes the cylinder relatively failsafe. The combination valve warns the driver if there is a problem with the brake system, and also does a few more things to make your car safer to drive.

THE MASTER CYLINDER

In the figure below, the plastic tank you see is the brake-fluid reservoir, the master cylinder's brakefluid source. The electrical connection is a sensor that triggers a warning light when the brake fluid gets low.

THE MASTER CYLINDER IN ACTION

When you press the brake pedal, it pushes on the primary piston through a linkage. Pressure builds in the cylinder and lines as the brake pedal is depressed further. The pressure between the primary and secondary piston forces the secondary piston to compress the fluid in its circuit. If the brakes are operating properly, the pressure will be the same in both circuits.

If there is a leak in one of the circuits, that circuit will not be able to maintain pressure. Here you can see what happens when one of the circuits develops a leak. When the first circuit leaks, the pressure between the primary and secondary cylinders is lost. This causes the primary cylinder

to contact the secondary cylinder. Now the master cylinder behaves as if it has only one piston. The second circuit will function normally, but you can see from the animation that the driver will have to press the pedal further to activate it. Since only two wheels have pressure, the braking power will be severely reduced.

DRUM BRAKES
Drum brakes work on the same principle as disc brakes: Shoes press against a spinning surface. In this system, that surface is called a drum.

Many cars have drum brakes on the rear wheels and disc brakes on the front. Drum brakes have more parts than disc brakes and are harder to service, but they are less expensive to manufacture, and they easily incorporate an emergency brake mechanism.

With drum brakes, fluid is forced into the wheel cylinder, which pushes the brake shoes out so that the friction linings are pressed against the drum, which is attached to the wheel, causing the wheel to stop.

In either case, the friction surfaces of the pads on a disk brake system, or the shoes on a drum brake convert the forward motion of the vehicle into heat. Heat is what causes the friction surfaces (linings) of the pads and shoes to eventually wear out and require replacement.

BRAKE CIRCUIT

BRAKE BLEEDING
Brake bleeding is the procedure performed on hydraulic brake systems whereby the brake lines (the pipes and hoses containing the brake fluid) are purged of any air bubbles. This is necessary because, while the brake fluid is an incompressible liquid, air bubbles are compressible gas and their presence in the brake system greatly reduces the hydraulic pressure that can be developed within the system. The same methods used for bleeding are also used for purging, where the old fluid is replaced with new fluid, which is necessary maintenance.

The brake fluid capacity of a typical automobile is around 250ml. Brake fluid is toxic, and must be handled carefully and disposed of properly. Most cars use DOT 3 or 4 Brake fluids, which may be mixed, but DOT 5 is silicone based and not compatible with DOT 3 or 4. One word of caution, most types of brake fluid harm paint and plastics on contact, so be careful. Brake fluid is water soluble so it may be rinsed with water.

BRAKE FLUID USED AT FORCE MOTORS :FMVSS dot 4 AIR PRESSURE OF BLEEDING :Main air pressure 4 bar Liquid button pressure 2.5 bar