Brakes and tyres department!!

-Vatsal jain
 BRAKES
Introduction:
• Brakes are mechanical
devices used for retarding
the motion of a vehicle.
• Brakes are also used to stop
the vehicle quickly within a
short distance.
• Brakes are also used to hold
the vehicle at rest
on an inclined road against
the pull of gravity.
 Construction
• Brake action starts as the brake pedal is depressed. Two sets of
members constitute the brake of every vehicle.
• One member is directly connected to the axle shaft and thus it
becomes a rotating member.
• The second member is attached to the frame or axle housing
and thus it acts as the stationary member.
• The brake works by causing friction between the non-rotating
member and the disc or drum that turns with the road wheel.
• Friction produces the force required to slow down the vehicle.
By means of friction, the brake converts the power of
momentum (kinetic energy) of the vehicle into heat.
• The heat produced, disappears into the air around the brakes.
Typical Brake System
 Hydraulic Principles

 Fluids cannot be compressed.

 Fluids can transmit Movement.
 Acts “Like a steel rod” in a closed
container.
 Master cylinder transmits fluid to wheel
cylinder or caliper piston bore.
 Fluids can transmit and increase Force.

Pressure = Force/Area
 Hydraulics

Simplified Hydraulic
Brake System.

Drum Brake.

Master Cylinder.

Disk Brake.
Hydraulic pressure is distributed
equally in all directions.
Same line pressure to all wheels.
The Hydraulic pressure is the same, but
the output force can be changed by the
piston size.
The output
Force can
be raised or
lowered by
piston size.
 Brake Pedal Design!
Advantage by Leverage!
 First Mechanical
Advantage is Driver’s
foot.
 Length of Lever
determines force
Applied.
 Uses Fulcrum (Efforts
are reduced to lift and
move things using lever.
 System Basics
Hydraulic actuation
allows multiplication of
pedal force.
In this system, a 10lb
force on the pedal
produces 360 lbs of
force at the friction
surface.
 Brake Fluid
 Properties of Brake
Fluid.
 Does not thicken or
then with changing heat.
 Must not boil.
 Must be compatible
with brake parts material.
 Must lubricate internal
parts.
 Must not evaporate
easily.
Brake Fluid types

DOT= Department of
Transportation.

DOT 3 and 4 :- DOT 5:-

 Poly glycol based. • Silicone Based.
 Most common. • Used only for heavy
 Compatible with one another.
damage paint.duty
 Inexpensive .
 Destroys paint. applications.
 Ruined by moister. • Not Compatible with
4&5.
Fluid Contaminates

 Moister- Lowers boiling point.

 water boils @ 212*F DOT 3 boils @
401*F.
 Petroleum Based Product- soften
rubber parts causing swelling.
 Dirt & Debris-
causes corrosion and clogs.
 Air and Vapors-
Compressible prevents pressure from
reaching brakes.
 Master Cylinder!!
Master cylinder is a control device that converts non-hydraulic pressure (commonly from a driver's
foot) into hydraulic pressure. This device controls slave cylinders located at the other end of the
hydraulic system.

 Provides a reservoir for brake

fluid and contains the driving
pistons in the hydraulic circuit.
 2 Types:-
Front - Rear split
-One piston for front brakes and one for rear.
-If a leak occurs you could lose front brakes.
Diagonally split
-One piston drives one front wheel and one
rear wheel.
-Diagonal layout allows you to maintain
directional control if a leak occurs.
 Bosch Tandem Master Cylinder!!
- Master brake cylinders must be -They are made of cast iron or
leakproof – and stay that way. aluminum.
- The high quality standard is
guaranteed by sophisticated
production methods and stringent
checks, with tight tolerance
specifications to ensure ideal
functioning and freedom from
leaks.
- The outstanding features of
-Optimized cylinder surfaces
Bosch master brake cylinders are
minimize cup abrasion and help to
their top quality and long service
maintain the long-term reliability
life.
of Bosch master brake cylinder.
 Power Booster in closed position
A power brake booster is a device that reduces the amount of force
that it takes to apply hydraulic brakes.
A typical vacuum brake booster
consists of a large, hollow
chamber that acts as a vacuum
reservoir or tank. This casing is
connected to manifold vacuum
via a check valve and a vacuum
hose. When the engine is turned
on, an a partial vacuum is
generated inside the intake
manifold, all of the air is sucked
out of the casing, which creates
an internal vacuum. This vacuum
Electromagnetic Brakes

 A brake is a mechanical device

which retards motion
 Electromagnetic brakes operate
electrically, but transmit torque
mechanically.
 This is why they used to be
referred to as electro-mechanical
brakes.
 Working Principle
The working principle of the electro
magnetic brake is based on the
creation of magnetic field with in a
metal disc rotating between two
electro magnets, which sets up a
force opposing the rotation of the
disc.
 Electromagnetic Braking
• Disc is rotated in magnetic field
• eddy currents will be produced in
disc
• eddy currents induced in disc will
produce a
torque (motor principle)
• produced torque in disc opposes
actual
rotation of disc (Lenz law)
 APPLICATIONS
 Already in use under some railway
system
 Can be used for any road vehicles
 Equally applicable to heavy and
light vehicles
 Can be used as additional retarder
for aircrafts
 Used in crane control system.
 Used in winch controlling.
 Used in lift controlling.
 Used in automatic purpose.
 Drum Brakes
A drum brake is a brake that uses friction caused by a set of shoes or pads
that press outward against a rotating cylinder-shaped part called a brake
drum.

 Expanding shoes create force

on the inner surface of the drum.
 Used on the rear of some
trucks and SUV’s.
 Requires less activation force.
 Require periodic adjustment.
Drum Brakes are of two types:-
1. Internal expanding
2. External expanding
• Internal expanding brakes have brake shoes
contained within the brake drums and expand
outwards to make contact with the rotating drum,
• whereas external expanding brakes contract to
make contact with the rotating drum.
Different parts of drum brakes:-

1.Brake drum 5. Anchor pin

2. CAM 6. Fixed wheel cylinder
3. Brake lining 7. Fixed wheel cylinder
4. Return spring
Drum Brake Assembly
 Brake drum materials
• Brake drums are made of nickel-iron casting; this metal
gives optimum rate of heat transfer and provides good
anti-wear qualities.
• Scooter and motorcycle brake drums are made of cast
aluminum with a bonded cast iron liner.
• The linings have high temperatures of about 3500 C
without distortion and are made of materials having high
coefficient of friction (0.4).
• The different lining materials are (i) molded pulp (ii)
compressed fabric, (iii) woven
 Rotors
A rotor is a part of a vehicle's braking system. It is roughly shaped like a flat-
bottomed bowl with a wide lip at the top. The calipers and pads of the brake
press against the sides of the rotor when the brake is applied, causing friction
to stop the vehicle.

There are two types of rotors:-

-- Vented rotors
-- Non vented rotors
 Vented Rotors Non vented Rotors

Vented Rotors
have Fins in the Non Vented
spaces Rotors
between their Or solid brake
machined rotors are used
surfaces. on smaller
These spaces vehicles, and
allow air to pass
have no cooling
through,
which helps carry fins.
heat away.
 Disc Brake
A disc brake is a type of brake that uses calipers to squeeze pairs of pads against a disc or "rotor"
to create friction. This action retards the rotation of a shaft, such as a vehicle axle, either to reduce
its rotational speed or to hold it stationary. The energy of motion is converted into waste heat
which must be dispersed.

Hydraulically actuated disc brakes are the most

commonly used form of brake for motor vehicles, but
the principles of a disc brake are applicable to almost
any rotating shaft.

Most modern cars have disc brakes on the

front wheels, and some have disc brakes on all
four wheels.
Different parts of disc brakes

1.Connecting tube
2. Cylinder
3. Piston
4. Friction pad
5. Hydraulic fluid
6. Brake disc
7. From master cylinder
8. Caliper
Disc brakes assembly:-
 Components of disc brakes
1. Disc 3. Friction Pads

2. Calipers
 Disc !!
• It is made of high-grade of gray
cast iron having pearlitic structure
to give better wear resistance
property.
• This disc, which rotates with the
car wheel, is efficiently cooled as
most of its area lies exposed.
 Types of Disc
-- Plain / simple Disc
- Surface of these disc is plain .
- There are no grooves no holes on the surface
of disc.
- Heat loss is less and on heavy load these disc
can be deformed.
-- Drilled disc
- Suitable for operating temperatures
and driving environments (especially
wet weather).
- Highest initial response.
- Thermal cracking if used
consistently at extremely high
-- Slotted Disc
- Stable braking feel at all temperatures, low disc
wear, and continuously refreshing the braking
surface for optimum performance.
- Low initial response as compared to drilled disc
type.

-- Slotted and drilled Disc

- Great initial bite in wet and dry conditions, superior
cooling capacity.
- Decreased brake fade, longer life, and fantastic looks. 
 Calipers Caliper Types

• These are of V-shaped type and are in There are 2 types of Calipers
two halves. Fixed Calipers are disc
Each half has a pad bonded to a steel brakes that use a caliper that
plate, a steel piston and a brake is FIXED in position and does
cylindrical housing bolted together. not slide. They have pistons
• Both these halves are hydraulically on both sides of the disc.
linked so that equal pressure may be There may be 2 or 4 pistons
applied on the pad through floating per caliper.
pistons. Floating calipers are disc
• Hydraulic pressure is applied only on brakes that uses a caliper
one side of the piston. that SLIDES.
 Fixed Caliper
 Applies two pistons to
opposite sides of rotor.
 Caliper stays stationary
 Disc Brakes require higher
hydraulic pressure.

•Motorcycles and some

import trucks and cars use
this type.
•Similar to bicycle brakes.
 Sliding Caliper

 Applies
pressure to two
pads on opposite
sides of Rotor.
 Caliper of the
brake moves.
 Friction Pads
• These are made of asbestos, fiber and
metal oxide fillers bonded with organic
compounds.
• Each pad is fixed to a steel plate that has to
take torque during braking on to the caliper.
• The pads may be of square, rectangular,
oval or segmental in shape.
• The size of the piston is made the same as
that of pads to avoid noise during braking.
• Rubber sealing rings prevent dust and
moisture to enter the piston housings.
 Working of disc brake
• When the driver applies pressure on the brake pedal, hydraulic pressure
pushes the pistons out from their housing.

• The pistons, in turn, press the brake pads against the moving disc faces,
causing friction and hence slowing it down.

• Hydraulic pressure is equally applied by the hydraulic fluid to the floating

pistons on either side.

• When the driver takes his foot off the brake pedal, hydraulic pressure on the
friction pads is released; the pistons move inwards and break their contact
with the disc.
Advantages of Disc Brakes over Drum Brakes
1.Disc brakes provide better stability since these have uniform
pressure distribution over the pads than that of the brake linings
in the case of drum brakes.

2. Increased temperature does not affect the disc pads much

compared to the brake linings of the drum brakes.

3. The design of the brake adjusters becomes simple because

when hot, the discs expand towards the pads causing no loss in
pedal travel.

4. Maintenance and repairs of disc brakes is easy.

 Disadvantages
1. Disc brake assemblies are costlier than drum brakes.
2. The pads wear off fast compared to brake shoe linings of drum brakes.
Disc brakes have higher brake pressures.
3. Complete protection to the disc from road residue is provided with great
difficulty.
4. The high temperature operation of disc brakes causes evaporation of the
brake fluid and weakening of seal.
5. In the case of cars fitted with disc brakes, an external servo mechanism is
required because these have no self energizing effect, Such an
arrangement is not required in cars having drum brakes.
6. Handbrakes can be installed on drum brakes because these have self energizing
effect. Disc brakes offer difficulty in installing hand brakes.
 Anti-Lock Brakes
An anti-lock braking system or anti-skid braking system (ABS) is an automobile safety system that
allows the wheels on a motor vehicle to maintain tractive contact with the road surface according to driver
inputs while braking, preventing the wheels from locking up (ceasing rotation) and avoiding
uncontrolled skidding.
 A locked (sliding) wheel
offers less braking force than a
decelerating rolling wheel.
 The locked wheel also
produces little lateral force,
preventing steering control.
 Anti-Lock systems (ABS)
monitor wheel lock-up and
modulate brake pressure to
provide controlled braking  Wheel speed sensors monitor each
under most circumstances. wheel speed.
 ABS controller and high-pressure
pump increase or reduce pressure to
wheels in order to maintain consistent
wheel speeds.
 Brake System for SAE Baja
Brake System:- The vehicle must have a primary
hydraulic braking system that acts on all wheels and is
operated by a single foot pedal. The pedal must
Brake Location:- The brake(s) on the driven axle
directly actuate the master cylinder through a rigid
must operate through the final drive. Inboard braking
link (i.e., cables are not allowed). The brake system
through universal joints is permitted. Braking on a
must be capable of locking and sliding all wheels, both
jackshaft through an intermediate reduction stage is
in a static condition as well as at-speed on pavement
prohibited.
and on unpaved surfaces.

Independent Circuits:- The braking system Throttle System:- The vehicle’s throttle system
must be segregated into at least two (2) independent shall be capable of fully actuating the throttle arm to full
hydraulic circuits such that in case of a leak or failure throttle (100%) on the engine and return to idle (0%
at any point in one system, effective braking power throttle) when released. The throttle shall remain in the
shall be maintained on at least two wheels. Each as-inspected condition for the duration of the event. Re-
hydraulic circuit must have its own separate fluid inspection is available by appointment with Briggs and
reservoir either through physically separate reservoirs Stratton at the event site. “Throttle-by-wire” or other
or by the use of a full-height dam in an OEM-style electronic throttle controls are explicitly prohibited.
reservoir.
 Tyre Wheel
Tyre:-
A rubber covering,
typically inflated or
surrounding an inflated
inner tube, placed round a
wheel to form a soft
contact with the road.
Wheel:-
- A wheel is a circular - A circular frame of hard
component that is material that may be solid,
intended to rotate on partly solid, or spoked and
an axle bearing. that is capable of turning on
 TYRE SIZE DESIGNATION:-
A Tyre is generally designated by its nominal
cross section code followed by the nominal
rim diameter code.

For radial tyres,

145/80R13

Section width (mm) Aspect Ratio Nominal Rim

Dia (inch)
Tyre Section
 Functions Of Tyre:-
 Provide Load Carrying Capacity.
 Provide Cushioning and dampening.
 Transmit driving and braking torque.
 Provide Cornering force.
 Provide floatation and dimensional stability.
 Resist abrasion.
 Generate steering response.
 Have low Rolling Resistance.
 Provide minimum noise and minimum
vibration.
 Be durable throughout and expected life
spam.
 Tyre Construction:-
BIAS:- RADIAL:-
 Cord strips are arranged diagonally to  Plies are laid at 90
the degree angles to Centre
Centre line of the tire. line of tire.
 Positive Qualities - strengthens the
sidewall  More sidewall
and stabilizes the tread area for contact movement and a
patch.
 Negative Qualities – Builds up smoother ride.
excessive heat;  Last longer than bias
very stiff and hard riding; get flat spots ply tires.
after
sitting in one spot and cooling down.
RADIAL:-
BIAS:-
 ADVANTAGE OF RADIAL TYRES:-

 50 - 100% LONGER LIFE - REDUCED COST PER

KILOMETER.
 5 - 10% FUEL SAVING.
 PUNCTURE RESISTANT - LESS DOWN TIME.
 RIDING COMFORT AND REDUCED CARGO DAMAGE.
 EXCELLENT HIGH SPEED CAPABILITY.
 EXCELLENT DAMPENING OF VIBRATIONS.
 EXCELLENT TRACTION & BRAKING ON BOTH DRY AND
WET ROAD.
 Tubeless Technology:- Tube Type:-
A tubeless Tyre is designed with a HalobutylA tube Type Tyre running at reduced
liner on the inner side which is applied from pressures generates more heat and is more
bead prone to damage.
to bead. A tube type Tyre is often easier to repair in
the bush than a tubeless one, because they
The Bead contour of tubeless tires are designed
to provide a self sealing mechanism between are easier to remove from the rim and are
the
tyre and rim. much easier to re- inflate.
ADVANTAGE OF TUBELESS Tubes do not strengthen the Tyre or help
prevent punctures.
TYRES:-
 Lower Rolling resistance
 Better handling Characteristics at high
speeds
 It is also reported, that air leakage after
puncture
is slower in tubeless tires than tube type tires
 Tyre selection
Tyre selection criteria based on Vehicle
dimensions :-

Wheel Base Tread Ground Clearance

 FAW / RAW
 Kerb Weight
 Gross Vehicle Weight
 Empty Vehicle Weight
 Pay Load
 Load Distribution
 Types of Tires !!
Standard tires:-- Also known as Stock Tyres or General Usage
tyres, these are usually the OE fitted tyres you
get with the car.
-- Since these are tested and approved by OE
manufacturers, most of the performance
parameters are optimized for general usage.

Touring tires:
-- Comfort is the main emphasis of these tyres.
Comfort not only stands for driving comfort
(Less vibrations), but also lower noise levels.
-- The tread patterns of Touring tyres are less
aggressive than Sporty tyres and have certain
design features on tread which create lesser
 Sporty tires: 
--These are designed for improving the grip and
handling of a vehicle are called performance
tyres.
-- They are designed to give maximum grip at
high speeds especially during dry and wet
weather conditions. 
-- Bit noisy at high speeds.

High Speed tires : 

--High speed tyres are available in Touring and
Sporty patterns.
--Their construction is more durable that can
resist high temperatures due to high-speed
rolling resistance and deal with strong G forces
under hard cornering. 
Eco-friendly Tires :
--Essentially, eco friendly tyres help reduce fuel
consumption by offering the lowest rolling
resistance possible.
--Low rolling resistance, as the name suggests,
is achieved by reducing friction losses in the
compounding.

Run Flat tires: 

-- They are designed to minimise loss of handling
of a vehicle after a tyre puncture has occurred.

--It allows the car to be driven on the punctured

tyre so that the driver does not have to change
the tyre for the small distance.
All-terrain tires: 
--All-terrain (A/T) tyres are usually found on utility
vehicles that frequently drive on varying surfaces
such as tarmac, dirt roads, sand, mud, rivers,
rocky terrain, etc. 
-- All-terrain tyres are usually made up of harder
rubber making them more durable than standard
road tyres in comparison. The sidewalls of these
tyres are also usually reinforced to withstand
impact from sharp rocks and other obstacles that
can be encountered on off road trails.
Highway-terrain tires: 
--These are supposed to run mainly On Road and
sometimes off road.

--Usually reinforced to withstand impact from

sharp rocks and other obstacles that can be
encountered on off road trails.
 Predictive Methods to Optimize Tyre Design:-
Tires determine to a great extent the dynamic
behavior of road vehicles.
Our attempt is to assist in bringing optimized synergy between the
mechanical characteristics of Tyre in contact with the road & the
mechanics of the vehicle so that Tyre vehicle system operates safely
under any circumstances & in a way that is satisfactory to
the driver.
Tyre Traction:-
Traction performance can be
characterized in many ways,
including braking, acceleration,
cornering, controllability, and
grade climbing. Though all
factors are important, the single
best indicator of tire
performance is braking
distance and deceleration.
 Functional Parameters:-
Tread Pattern:-
RIB PATTERN : The pattern along the circumference of the Tyre
Good points : Lower rolling resistance. Good directional stability
and
steering control thanks to lateral resistance. Suitable for sustained high
speeds thanks to low heat generation.
Bad points : Poor braking & acceleration grip on wet roads.
Stress caused.
by flex means tread is more susceptible to cracking.
Use : For paved road surfaces and the steering wheels of trucks or
buses.
LUG PATTERN : The groove pattern perpendicular to the
circumference of the Tyre.
Good points : Excellent braking & driving power. Superior traction.
Bad points : Noisy at high speed. It's not suitable for high speed
driving
because of high rolling resistance.
Uses : For dirt roads, rear wheels of buses, industrial vehicles and
dump.
SEMI-LUG PATTERN : The combination of Rib-
shape & Lug-shape.
Features : The rib in the center provides
directional control whilst the shoulder.
lug gives good braking & driving power.
Uses : Good for both paved and dirt roads.
Usually used in both front & rear.
wheels of trucks and buses.

BLOCK PATTERN : The pattern of independent

block which the groove is connected with
each other
Good points : Good steering control and stability on
snow covered and wet
roads. Good water dispersal properties on wet roads.
Bad points : Tyre wear is heavy as tread blocks are
finer.
Uses : Suitable for winter or all-season passenger car
tires. Suitable for back wheel
of Radial Tyre of ordinary car .
ASYMMETRIC PATTERN :
Tread pattern differs on either side
Good points : Good for high speed cornering
thanks to greater contact area.
Reduces tread-wear on outside of Tyre.
Bad points : You must position them the right way
around.
Uses : High performance and motorsport tires.

DIRECTIONAL PATTERN : Lateral grooves on both sides

point the same direction.
Good points : Good driving force and braking
performance. Good water dispersal
means good stability on wet roads. Correct choice for fast
driving styles.
Features : mounted in direction of tread pattern.
Uses : the passenger car tyre for high speed usage.
 Tyre problems:-
Feathering
• Improper alignment (TOE).
• Worn or damaged steering/ suspension parts.
• Hard cornering.

Cupping
•Worn or damaged steering or suspension parts.
•Improper balancing.

One Edge
•Improper alignment (CAMBER).
•Worn or damaged steering or suspension
parts.
 Wheel - Basics
•Most standard wheels are made of steel.
•Some vehicles are fitted with alloy wheels
that are made of magnesium or aluminum
.
•The rim holds the Tyre. Rim
•Well of the wheel allows the Tyre to be
removed and refitted .
•Centre section is welded to the rim.
Pilot bore fits to the hub.

Centre mounting section

 Wheel - Basics

Two-piece Split Side rings

Three-piece Flange or
Continuous rings

If any components are damaged the rim must be

replaced .
 Valve Stems and Cores
Functions – Retains air, allows inflation and deflation.
Valve core Valve stem

Rubber stem of the valve is pulled into the wheel.

Valve core contains a spring loaded air valve insert.
The valve core also has a sealing washer and a seat Seat
washer. washer
Valve cap keeps out dust and helps keep air in.

Tyre pressures must only be checked and Sealing

washer
adjusted when the Tyre is cold.
Valve caps
 Wheel Fixings:-
-Wheel studs and nuts attach the wheel to the hub.

-Wheel studs press through the hub or axle flange.

-Taper on the wheel nuts secures and centers the

wheel.
-Wheel studs usually have a right-hand thread.

-If it is a left-hand thread, it can be marked with “L”.

-Metric threads are marked with “M” or METRIC.

 Wheel Nut Torque

Correct torque of wheel fixing is vital for

all vehicles, and nearly all require the use
of a torque wrench.
Excessive torque can lead to wheel or hub
distortion, causing runout and vibration.
Low torque may allow wheel nuts to work
loose and wheels to come off.
Nuts should always be tightened in a
diagonal pattern.
Wheel Rim Size
 Run Flat Tires
•Temporarily supports weight of vehicle
even with no air pressure .
•Internal support, thicker and stiffer side
walls, stronger beads.
•Can maintain Mobility for upto 100 km
at slow speed (60 kmph) .
Front toe:-
Rear toe:-
Thrust angle:-
Camber:-
Castor:-
Thank you!!

-Vatsal Jain