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International Research Journal of Engineering and Technology (IRJET)

e-ISSN: 2395-0056

Volume: 12 Issue: 04 | Apr 2025

p-ISSN: 2395-0072

www.irjet.net

Design, Analysis and Fabrication of Hydraulic Braking System Siddhesh Agone1, Siddhesh Sondkar2, Biswajit Behera3, Sumit Ghodke4 Prof. Nilesh Shinde, Dept. of Mechanical Engineering, Datta Meghe College of Engineering Airoli, Maharashtra, India. ---------------------------------------------------------------------***---------------------------------------------------------------------

Abstract - This report contains a brief overview of the braking system for an (All-terrain vehicle) ATV. Brakes play a crucial role in vehicles by helping to slow down, stop, or keep them stationary. Among modern braking systems, brake discs are key, especially in automobiles. The biggest challenge with brake discs is controlling the heat generated during braking. If this heat isn’t adequately dissipated it can cause the disc to heat up or cool down too quickly, leading to thermal stress and, in extreme cases, failure. In this study, we will explore the use of stainless steel material for brake discs, given its promising frictional properties and ability to conduct heat efficiently and lightweight properties. A disc brake rotor model for the all-terrain vehicle was simulated using ANSYS software for thermal analysis. We calculated heat flux, and kinetic energy and studied how pressure and frictional forces act on the brake material. The goal is to understand how these forces affect braking performance and how design changes like disc design for better heat dissipation, and a change in pedal ratio will improve driver reach. Material selection and material differentiation of material is also included in the report. The end of the report contains the calculations and iteration based on which we have designed the system.

vehicle (ATV) featuring a brake rotor of stainless steel, an independent pressure switch(one switch for the rear and one switch for front), newly designed brake pedal. The dual pressure switch with enhanced safety by introducing a fail-safe mechanism; if one switch malfunctioned the other remains functional, thereby reducing the risk of total failure. Our approach is for both performance and reliability. The use of a hydraulic braking system will reduce pedal effort, while a disc brake will have higher heat dissipation and consistent braking force under varying conditions. This paper contains conceptualization, design methodology, component selection, material selection, and performance analysis of the braking system, to contribute safer and more efficient braking technologies in automotive engineering all-terrain vehicles. 1.1 LITERATURE REVIEW Reddy S. and Venkatesh G. performed an analysis of the inboard and outboard braking systems in rear-wheel drive ATVs. The analysis has contained testing under heavy-duty trail conditions. The result showed that inboard brakes suffered slightly delayed response time due to drive train backlash.

Key Words: Hydraulic braking system, All terrain vehicle, Disc (rotor), Pressure switch.

1. INTRODUCTION

Patel R. and Mehta S. conducted a study analyzing the performance of hydraulic disc brakes used in off-road vehicles, especially focusing on all-terrain vehicles (ATVs). Their research targeted braking force distribution across the front and rear wheels under different terrain conditions. Using simulation tools like ANSYS and SolidWorks motion, Authors analyze brake pressure, stopping distance, and dynamic load transfer. Results showed that dual hydraulic switches with pressure distribution provide better control and reduce stopping time, especially on slopes and unstable surfaces.

Braking is one of the most important aspects of vehicle safety and performance it has the ability to stop or slow down a vehicle safely which ultimately defines a vehicle’s control and reliability. The braking system is not just a mechanical necessity but also a safeguard, a lifesaving feature that every vehicle depends on. A braking system serves three fundamental purposes: To reduce vehicle speed, to bring the vehicle to a complete halt at a desired point, and most importantly, to prevent accidents by providing the driver with complete control over the motion of the vehicle. This is achieved by converting the vehicle’s kinetic energy into heat energy through friction, then the heat is dissipated into the atmosphere. While this energy transformation may seem simple, it involves complex mechanical and thermal processes that must be carefully managed to ensure efficiency, consistency, and safety.

Khan M.A. and Patel N. did a comparative study on brake disc materials such as cast iron, stainless steel, and carbon ceramic composites used in the hydraulic braking system of ATVs. The materials were evaluated based on thermal conductivity, wear resistance, and weight. Through thermal structural FEA and lab-based wear testing, the study found that carbon ceramic composites had higher heat resistance and less weight but at a higher cost, while cast iron is cheaper but has the highest thermal deformation. Stainless steel is a balanced option with moderate weight and good corrosion resistance, making it ideal for off-road conditions.

In this research, we present a design analysis and fabrication of a hydraulic braking system in an all-terrain

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