aUTOMOBILE NOTES

5/23/2016
Brake
Module 4
Braking system provides added friction to slow

or stop the vehicle
Converts kinetic energy into heat
FAJ/ Presntation AE/ 2013-17-A Batch
Requirements
Brake capacity
1. Brake
2. Chassis
3. Tyre
1.
2.
3.
4.
5.
6.
7.
8.
Stopping distance
Reliable
Less driver effort
Un affected by water, dust, heat and
weather
Min wear and tear
Withstand the stress and strain in braking
Heat dissipation
Good tyre
Unit pressure /w braking surface

Friction coefficient
Heat dissipation
Projected friction area
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Classification
1. Mechanical
2. Hydraulic
3. Power
1.
2.
3.
4.
Mechanical
Externally contracting brake
Internally expanding brake
Air
Air hydraulic
Vacuum
electric
Hydraulic brake System
Fluid flow
1. Drum Brakes
2. Disc Brakes
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Brake fluid
Withstand cold temp and high temp
Department of transportation (DOT 3)
Boiling point 460 F
Proportioning valve
Distributes fluid to front and rear wheels
Harder u pedalmore pressure on front wheels
and less on rear
Pressure Differential valve
Brake Lines
Non corrosive seamless steel tubing
Measure pressure b/w two chambers of master

cylinder
If their s difference indicator turns on
Drum Brakes
Components
1.
2.
3.
4.
5.
6.
7.
Brake drum
Back plate
Brake shoes
Brake liners
Retaining spring
Cam
Brake linkages
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Master Cylinder
Wheel Cylinder
Disc Brake
Brake Pads
Rotor
Caliper
Floating
Fixed
Caliper Support
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Four Piston Fixed Caliper
Single piston
floating Calipers
Air brake
Components
Reservoir
Compressor
Unloader valve
Air dryer
System protection valve
Brake chambers
Brake valve
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Power Brake
ABS
Vacuum Assist Power Brakes
HYDRAULIC ACTUATOR
WHEEL SPEED SENSOR
ELECTRONIC CONTROL UNIT
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Chassis
Structure consisting the foundation upon
which all the other components of a vehicle is
assembled.
Its consists of: Engine
Running gear
Drive line
Electrical units
Components
Engine produces power for propulsion
Radiator to carry away the excess heat from
the engine
Clutch to isolate engine from transmission
system as and when required.
Gearbox provides the torque to propel the
vehicle
Universal joints and propeller shafts
transmits torque to final drive.
Final drive - transmits torque to half axles from propeller

shaft.
Differential
Half axle drives
Frame
Springs and wheels
Shock absorbers
Electrical system
Steering system
Brake system
Engine control system
Power train control system
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Classification
According to the fitting of the engine
Full forward engine outside the driver cabin Eg.
Cars
Semi forward half portion of engine inside the
driver cabin Eg. Tata SE series Vehicle
Bus chassis engine in driver cabin
Centre engine Eg. Royal tiger bus of Delhi
Transport
Back engine Eg. Volvo
Classification
According to the number of wheels and
number of driving wheels
4*2 4 wheels in which 2 are driving wheels
Classification
Frame
According to wheel base

Wheel base distance b/w centre of front and
rear wheel
Long wheel base more floor area
Front and rear overhang is more
Other parts are mounted

Rigid part
Skeletal wrk
Wheel and tyre support frame
Rear axle hosing at rear end with rear springs
Chassis frames are made of steel section
Rigid
Withstand load
Light weight
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Functions
Long members
Cross members
Long members bend at front and rear to
accommodate axles
To carry load
To support the load of body, gear, etc
To withstand stress due to road terrain
To withstand centrifugal force while cornering
To withstand forces while braking
Types of Frames
Conventional Frame
1. Conventional frame
2. Integral frame
3. Semi integral frame
2 long side members

5 -6 cross members
Joined with rivets and bolts
Cross sections used are
Channel resistance to bending
Tubular torsion
Box bending and torsion
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Integral Frame
No frame
All parts attached to body
Body will perform the function of frame
Cheaper
Low weight
Economic
Difficult to repair
Semi Integral Frame

Half frame is fixed in front end engine , front
suspension and gear box
Repair is ease
Different loads on frames
Body
Short loads - bumps

Momentary loads -taking curves
Impact load collision
Inertia braking
Static load
Over load
Types
Commercial
Passenger
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Vehicle Body Engineering-Crumple

Zones
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Tyre
DEFINITION
A tire (or tyre in British English) is a ringshaped covering that fits around a wheel to
protect it and
enable better vehicle performance by
providing a flexible cushion that absorbs shock
while keeping the wheel in close contact with
the ground.
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TYRE CROSS SECTION
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CONSTRUCTION DETAILS.
The bead
Layers of rubber coated high tensile steel wires formed into
inextensible loops
is a loop of high-strength steel cable
coated with rubber.
gives strength to stay seated on the wheel rim
to handle the forces applied by tire.
Belts
made from steel

to reinforce the area under the tread.
provide puncture resistance
help to stay flat so that it makes the best contact with
the road.
DETAILS
cap plies,
Plies
reinforcing members of the tyre
made from rubber coated fabric (Rayon, Nylon,
Steel, Polyester etc)
an extra layer or two of polyester fabric

help hold everything in place.
Optional
used on tires with higher speed ratings
Sidewall
layers of appropriate thickness of rubber compound
applied on both sides of the tyre carcass between the
beads and tread
provides lateral stability
protects the body plies
helps keep the air from escaping.
help increase the lateral stability.
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DETAILS
The tread
CLASSIFICATIONS
TYRES
The portion of the tyre, which comes in contact

with the road
provide the necessary traction, wear resistance
Mixture of many kinds of natural and synthetic
rubbers.
The tread and the sidewalls are extruded and cut
to length.
allow for low heat build up and low noise
Bias
Belted bias
Radial
Solid
Bias
body ply cords that extend diagonally from bead to
bead,
usually at angles in the range of 30 to 40 degrees,
with successive plies laid at opposing angles forming
a crisscross pattern to which the tread is applied.
The design allows the entire tire body to flex easily,
providing the main advantage of this construction, a
smooth ride on rough surfaces.
This cushioning characteristic also causes the major
disadvantages of a bias tire: increased rolling
resistance and less control and traction at higher
speeds.
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Belted bias tyre

It starts with two or more bias-plies to which
stabilizer belts are bonded directly beneath
the tread.
This construction provides smoother ride that
is similar to the bias tire, while lessening
rolling resistance because the belts increase
tread stiffness.
The plies and belts are at different angles,
which improves performance compared to
non-belted bias tires. The belts may be cord or
steel
Radial
This construction utilizes body ply cords extending

from the beads and across the tread so that the
cords are laid at approximately right angles to the
centerline of the tread, and parallel to each other, as
well as stabilizer belts directly beneath the tread.
The belts may be cord or steel.
The advantages of this construction include longer
tread life, better steering control, and lower rolling
resistance.
Disadvantages of the radial tire include a harder ride
at low speeds on rough roads and in the context of
off-roading, decreased "self-cleaning" ability and
lower grip ability at low speeds.
Advantages
Longer tyre life
Improved fuel efficiency due to Reduced rolling resistance .
Better high speed performance: Better dimensional &
directional stability due to reduced edgewise bending.
Better Vehicle handling due to:
Minimum distortion in foot print area
Higher flexibility of sidewalls
Reduced side slip
Greater traction , improved braking & cornering stability

due to:
Larger footprint
More Uniform Pressure Distribution
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Solid
Specifications
Solid tires include those used for lawn mowers,

skateboards, golf carts, scooters, and many types of
light industrial vehicles, carts, and trailers.
One of the most common applications for solid tires
is for material handling equipment (forklifts). Such
tires are installed by means of a hydraulic tire press.
Inflation Pressure
Load Rating
Speed Rating
Service Rating
Retread
Performance characteristics
a process of buffing away the worn tread and

applying a new tread
Methods
the mold or hot cure method
Thread wear
Wet traction
Balance
Rolling resistance
the pre-cure or cold one
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Tire code
Explanation of tire codes
This code specifies the dimensions of the tire,

and some of its key limitations, such as loadbearing ability, and maximum speed.
The European Tyre and Rim Technical
Organisation (ETRTO) and the Tire and Rim
Association (TRA) are two organizations that
influence national tire standards.
Tubeless tyre
The tyre and rim assembly form an air
container, to Seal and Contain the
compressed air inside the assembly
pneumatic tyres that do not require a
separate butyl rubber inner tube
which has an inner lining of impermeable
halobutyl
valve is directly mounted on the rim
If a tubeless tyre gets punctured, air escapes
only through the hole, leading to a gentle
deflation of the tyre
Advantages
More economical
Since tube is eliminated , friction between tyre & tube is
not experienced
lower rolling resistance, I
mproved fuel efficiency,
less vibrations ,
less heat generation and better comfort.
Chances of tube getting pinched under the bead while
mounting are eliminated
The number of components used in a tyre wheel assembly
gets reduced
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Sudden air loss is avoided

Bead will not displace easily from rim in case
of a puncture
Maintenance of Tyre
Proper inflation
Running a flat tyre
Keeping grease and oil away
Equalizing traction same dia in rear wheels
Alignment of wheels
Side skidding and rounding corners rapidly
Setting brake suddenly loose and worn
treads may be damaged suddenly
keeping rims in good order

Examine the tyres occasionally
Sudden locking of rear wheels with brakes
Tyre wear
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5/23/2016
Wheel
Support all weight of vehicle
Convert rotary motion into longitudinal
motion
Types
Pressed or disc wheel
Simple and robust

Ease in mfg
Simple cleaning
Low maintenance
1. Pressed or disc wheel

2. Wire wheels
3. Light alloy casting wheel
Construction
Wire Wheels
Have a steel rim and a disc

Rim is welded to flange of disc
Wheel is bolted to brake drum
Slots near rim provides brake cooling
A hole in disc accommodates tube valve
A cover is used to protect from dirt and dust
Early model
Ease in mounting
Simple construction
Better cooling
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5/23/2016
Construction
Hub connected to rim through spokes
Spokes
Headed inner end hob hole
Threaded outer end rim holes mushroom
headed tubular nuts are used to tight
Alternate spokes are screwed forward and
backward towards the rim
Forward sloping spoke absorb braking torque
Backward sloping driving torque
Construction
Holes in hub arranged in inner and outer
rows
Spoke slope towards rim frm outer row
Also second set spoke slope outwards to the
rim from inner row
Side ways inclinations of the spoke hold the
wheel upright against cornering loads and side
thrusts
Light alloy casting wheel

Aluminum or magnesium alloys
Wider rims
Good adhesion
21

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5/23/2016

Braking system provides added friction to slow

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

Unit pressure /w braking surface

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

Hydraulic brake System

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

Pressure Differential valve

FAJ/ Presntation AE/ 2013-17-A Batch

Measure pressure b/w two chambers of master

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

Four Piston Fixed Caliper

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

Vacuum Assist Power Brakes

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

Final drive - transmits torque to half axles from propeller

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

According to wheel base

Other parts are mounted

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

2 long side members

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

Semi Integral Frame

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

Different loads on frames

Short loads - bumps

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

Vehicle Body Engineering-Crumple

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

TYRE CROSS SECTION

FAJ/ Presntation AE/ 2013-17-A Batch

FAJ/ Presntation AE/ 2013-17-A Batch

made from steel

FAJ/ Presntation AE/ 2013-17-A Batch