Design and Experimental Analysis of Hydraulic Braking System for All-Terrain Quad Bike

Sairaj Madhukar Rapartiwar, Manas Kishor Thakur

Abstract: In preceding years, mechanical braking systems, often relying on cables, rods, or levers, were the standard in braking applications. These systems exhibited notable limitations, including inconsistent brake force distribution, high maintenance requirements, and reduced efficiency under high-speed and high-load conditions, ultimately affecting overall braking performance. Hydraulic braking systems have been widely adopted to address these shortcomings, particularly in the automotive sector, due to their enhanced reliability and efficiency. Building on these advancements, the current study focuses on the design and development of a hydraulic braking system with a dual-actuation circuit tailored for a quad bike, a specialized All-Terrain Vehicle (ATV). The dual actuation circuit mitigates the drawbacks associated with single-circuit systems by optimizing key parameters critical to braking performance, such as force distribution and response time, thereby significantly improving braking efficiency. The study incorporates a systematic approach to material selection for the brake disc, ensuring optimal thermal conductivity, wear resistance, and structural integrity under high-stress and high-temperature conditions. Material selection was conducted to meet the specific demands of high-performance ATV braking systems, balancing manufacturability and cost-effectiveness. The research methodology included extensive analytical iterations to determine appropriate braking parameters. A Finite Element Analysis (FEA) was conducted on critical components, such as the brake disc to evaluate stress distributions, deformation, and thermal performance under dynamic conditions. Simulation results were validated experimentally, employing a test rig designed to replicate real-world ATV braking scenarios. Additionally, a design trade-off analysis was performed to balance parameters like design space, manufacturability, and cost constraints, ensuring a practical yet optimized braking system. The comprehensive characterization of the hydraulic braking system and its dual actuation circuit provides a robust framework for enhancing braking systems in similar ATVs. The findings offer a novel pathway for integrating hydraulic braking designs into off-road vehicle development, emphasizing reliability and performance.

Keywords: hydraulic braking systems, quad-bike, All-Terrain Vehicle (ATV), dual actuation

How to Cite?: Sairaj Madhukar Rapartiwar, Manas Kishor Thakur, "Design and Experimental Analysis of Hydraulic Braking System for All-Terrain Quad Bike", Volume 14 Issue 7, July 2025, International Journal of Science and Research (IJSR), Pages: 329-336, https://www.ijsr.net/getabstract.php?paperid=SR25629162502, DOI: https://dx.doi.org/10.21275/SR25629162502