International Journal of Engineering Technology Science and Research

IJETSR
www.ijetsr.com
ISSN 2394 – 3386
Volume 5, Issue 3
March 2018

Vehicle Brake Failure and Road Accidents- An Investigation

Author 1 Name* Anant W. Nemade

Lecturer in Mechanical Engineering, Government Polytechnic, Aurnagabad (M.S) India
Author 2 Name* Samir A. Telang
Lecturer in Automobile Engineering, Government Polytechnic, Aurnagabad (M.S) India
Author 3 Name* Dr. Arvind L. Chel
Associate Professor, Department of Mechanical Engineering,
MGM’S Jawaharlal Nehru Engineering College, Aurangabad ( M.S.) India

Abstract: Road accidents are an outcome of the interplay of various factors, some of which are the length of road
network, vehicle population, human population and adherence/enforcement of road safety regulations, vehicle
component failure etc. of which some parameters are difficult to control or can be controlled by external factors such as
strict traffic norms, rigorous driving tests for license, traffic separation etc. But accidents due to failure of vehicle brake
is a prime responsibility of vehicle manufacturer, the brakes must work properly without failure of any component in its
assembly. Road accident causes injuries, fatalities, disabilities and hospitalization with severe socio economic costs
across the country. Consequently, road safety has become an issue of concern both at national and international level.
The United Nations has rightly proclaimed 2011-20 as the Decade of Action on Road Safety. India is also signatory to
Brasilia Declaration and is committed to reduce the number of road accidents and fatalities by 50 per cent by 2020.
Keywords: Brakes, Disk, Drum, Accidents, vehicles.

1.0 INTRODUCTION mechanical brakes component system in vehicles

Now a day's increasing road accidents is the worry
area of every human- being, road and safety
department of central government and state
government are trying very hard to control the road
accidents by different methods. According to the
recent report of central government, Maharashtra
state is at the 2nd Position in road accidents
throughout the India,[1] Therefore safety has
acquired a priority. Road accidents have too many
reasons; some of the reasons are drivers fault, road
conditions, vehicle maintenance, overloading and
uncontrolled driving, excessive speed or aggressive
driver behaviour, vehicle component failure etc.
However whenever accident happens one thing is
sure that every driver will apply brakes as this is the
active safety provision provided to vehicle to stop
the vehicle, other problems are secondary in nature.
If the brakes components works properly then the
accidents can be avoided up to large extend.
Therefore sudden failure of brakes component is
also one of the problems for accident. The paper
explores the reliability and safety assessment in
and its impact on the road accidents.
2.0 LITERATURE REVIEW
Between 1970 and 2010, the number of accidents
increased by 4.4 times with 9.3 times increase in
fatalities and 7.5 times increase in the number of
persons injured, while there was an increase of 82
times in the number of registered motor vehicles
and more than three times increase in the road
network. [2]. However, with one of the highest
motorization growth rate in the world accompanied
by rapid expansion in road network and
urbanization over the years, our country is facing
serious impacts on road safety levels. The total
number of road accidents increased by 2.5 per cent
from 2014 to 2015. The total number of persons
killed in road accidents increased by 4.6 per cent
from 2014 to 2015. Road accident injuries have also
increased by 1.4 per cent from 2014 to 2015. The
severity of road accidents, measured in terms of
number of persons killed per 100 accidents has
increased from 28.5 in 2014 to 29.1 in 2015. During
2015, thirteen top States namely Tamil Nadu

1009 Anant W. Nemade, Samir A. Telang, Dr. Arvind L. Chel

 International Journal of Engineering Technology Science and Research
(69,059), Maharashtra (63,805), Madhya Pradesh
(54,947), Karnataka (44,011), Kerala (39,014),
Uttar Pradesh (32,385), Andhra Pradesh (24,258),
Rajasthan (24,072), Gujarat (23,183), Telengana
(21,252), Chattisgarh (14,446),West Bengal
(13,208) and Haryana (11,174)together accounted
for 86.7 per cent of all road accidents in the country.
Tamil Nadu has reported the highest number of road
accidents and number of persons killed in road
accidents. [2] A comparison of States which
accounted for 83.6 per cent of share in road accident
fatalities during the calendar year 2015 reveals that
Uttar Pradesh stood on top in road accident fatalities
in the entire country with a percentage share of 12.1
per cent followed by Tamil Nadu 10.7 per cent and
Maharashtra 9.0 per cent. Total Number of Persons
Killed in Road Accidents (in %) in 2015 Share of
10 States Uttar Pradesh 12.%. Tamil Nadu 10.7 %.
Maharashtra 9.0 %. Karnataka 7.4 %. Rajasthan 7.2
%. Madhya Pradesh 6.4 %. Andhra Pradesh 5.7 %.
Gujarat 5.6 %. Telangana 4.9 %. West Bengal 4.3
% [3].
Another research work focuses in identifying the
modes of failure in various automobile components
and tends to identify suitable methods to avert such
replacements. Though methods cannot be devised to
avert completely the replacement, there are methods
that when implemented could prolong the period of
use of the component in the system.[4]
In another research paper it has been stated that if
brake failure is occur then the buzzer give the
indication to the driver in the form of sound and
simultaneously alternative braking system start their
working and apply the secondary brakes by using
motor fitted to the chassis, as the result of these the
speed of the vehicle get reduced and vehicle is stop
in some second.[8]
3.0 FAILURE OF BRAKE COMPONENTS
Manufacturers are required by law to design and
engineer cars that meet a minimum safety standard.
While advancements are being made every day to
improve the safety and efficiency of automobiles on
the road, problems with the design and functionality
of the cars themselves sometimes referred to
as product liability is one of the top causes of car
accidents on the road. Even with safety standards
and extensive testing on every automobile
manufactured, there are significant amount of
defective cars on the road. [5]. There are three main
1010 Anant W. Nemade, Samir A. Telang, Dr. Arvind L. Chel
IJETSR
www.ijetsr.com
ISSN 2394 – 3386
Volume 5, Issue 3
March 2018
types of system components where system failure
may occur are.
Operational Failure: Human operators may
operate the system incorrectly.
Software Failure: Software fails due to errors in its
specification, design or implementation.
Hardware Failure: It may fail because of its design
and manufacturing errors.[9]
The role of operator is always important in braking
system of any motor vehicle, unless and otherwise a
positive signal by operator system will not be
active. The brakes will not be applied unless and
until the driver wishes to operate it in a required
manner. The role of software has increased in
modern braking system such as ABS-Antilock
Braking System, TCS- Traction Control System,
ESP- Electronic Stability Programme, AEB-
Autonomous Emergency Braking, EBD or EBFD-
Electronic brake force distribution, EBL- Electronic
Brake Force Limitation etc. the failure of software
in this system will lead in to accidents. Software
assists to operate the hardware at an accurate rate
and time. This system mostly works on feedback
system, in modern vehicles failure of software
systems are indicated by the vehicle well in
advance. However, this does not suggest that the
failure analysis of such system is always easy, but
in essence is straightforward. In contrast, the failure
of hardware (Mechanical Components) system is
difficult to predict. This paper investigates the
failure modes for mechanical braking system of car
segment with hydraulic braking system.
4.0 OBJECTIVE OF THE STUDY
Modern braking system is using sophisticated
controlling systems to operate the brakes which
include software and electronic sensors, but the
basic mechanical braking system is same. The
components required to bring running wheel at rest
are same; called mechanical components such as
disc, drum, pads, master cylinder, piston, shoes,
tubing, pedal, oil, springs etc. Basically we are
developing the modern braking system on the basic
of mechanical brake system, therefore there is need
to study in this area for avoiding component failure
of brake while in operation. The research work
focuses in identifying the modes of failure in
hydraulic braking system. The objective of the
investigation is to produce awareness which may
 International Journal of Engineering Technology Science and Research
help to rectify problems associated with mechanical
components of brakes to avoid failure of brake
system and improve the reliability as well as
productivity in car segment.
5.0 MECHANICAL BRAKE COMPONENTS
In modern vehicles mostly braking actuation action
is taking place in three modes are Actuation by
Hydraulic fluid, Actuation by Pneumatic pressure
and Actuation by Electric or Electronic system. In
car segment mostly hydraulic braking system is
used.
The major hydraulic braking systems are
combination of drum brake and disk brakes.
Fig-1: Hydraulic Braking System
5.1 Failure in Drum brakes:
Fig-2: Drum Brake
In car drum brakes are generally used in the rare
wheel. The components associated with drum
1011 Anant W. Nemade, Samir A. Telang, Dr. Arvind L. Chel
IJETSR
www.ijetsr.com
ISSN 2394 – 3386
Volume 5, Issue 3
March 2018
brakes are: Back plate, Brake shoes, wheel
cylinders, piston, Drum, Adjuster, and springs. The
back plate is used to attach all the components of
brake system, it necessary to inspect whether the
riveting is proper or not. The wheel cylinders are to
be properly checked for erroneous operation to
prevent any sudden failure. The fluid pressure is
equally distributed to front wheel calliper systems
and the rear wheel cylinder drum. The main failure
of cylinder is fluid leakage. The pressure is applied
by pedal The brake pedal exists to multiply the
force exerted by the driver’s foot. From elementary
statics, the force increase will be equal to the
driver’s applied force multiplied by the lever ratio
of the brake pedal assembly:
F0= Fd X { L2÷L1 }
where F0 = the force output of the brake pedal
assembly
Fd = the force applied to the pedal pad by
the driver
L1 = the distance from the brake pedal arm pivot
to the output rod clevis attachment
L2 = the distance from the brake pedal arm pivot
to the brake pedal pad
Note that this relationship assumes 100%
mechanical efficiency of all components in the
brake pedal assembly. In practical application, the
mechanical deflection of components and friction
present in physical interfaces prevents this
condition. It should be properly inspect. The K.E.
possessed by the vehicle depends upon the weight
and the speed of the vehicle. The energy must be
dissipate when the vehicle is stopping, at one time it
converts in to heat due to friction.
KE=1/2 MV2
Where M= mass of vehicle in KG
V = Speed of vehicle in m/s
Therefore work done in bringing the vehicle at rest
is
W=F x S
Where F= average braking force in N
S= distance travelled in m
While braking a moving vehicle to stop the vehicle
work done must be equal to initial kinetic energy
possessed by the vehicle.
KE=W
 International Journal of Engineering Technology Science and Research
1/2 MV2 = F x S
Average Braking Force is
F= MV2 / 2S N
Contaminants on the brake shoes will also aid the
faster deterioration of the performance of the real
wheel cylinder. Wheel cylinder cups also cause
failure to a certain extent. The cylinder bore may in
due course of time be worned out, pitting, scorching
discoloured and this required immediate honing. If
the worning out is high, then the entire system has
to be replaced. Failure piston is also cause of brake
failure. The piston movements must be proper, there
should not be obstacle for movement because of
worn-out O- rings. Drum must be clean enough,
there should not be scratches on the braking area
which reduces the friction between brake shoes and
liner. Adjuster must be rigid, it should not be
disturbed by the movement of brake shoes, also it
must give proper movement while making
adjustment. Springs must provide equal amount of
force for retardation of brake liner. The elasticity of
spring must not lose due to continuous operation at
high temperature during braking.
5.2 Failure in Disk Brakes:
Fig-3: Disk Brake
Brake calipers are the vital components in any disc
brake assembly. In a disc brake the rotor speeds in
controlled by created by a caliper that creates a
source of friction between itself and the rotor. Brake
pads engage itself in the process creating friction.
1012 Anant W. Nemade, Samir A. Telang, Dr. Arvind L. Chel
IJETSR
www.ijetsr.com
ISSN 2394 – 3386
Volume 5, Issue 3
March 2018
Important causes of failure are the fluid leak in the
braking system. The fluid leak is prevented by the
soot’s and seal. Due course of operation, heating of
braking systems will cause wearing of the seals,
causing fluid to leak and the brake caliper to fail.
Calipers have to be operated at an optimum fluid
pressure. Hence the fluid system plays an important
role.
Another failure in the disc brake caliper is that the
seizure of the piston of caliper. The main causes of
seizure are: Piston corrosion, Caliper boot damage,
Moisture between bore and piston. Disk brake needs
more care than the drum brakes as are more
exposed to atmosphere.
In both type of braking system tubing plays vital
role. It should be designed to withstand the required
pressure and material should be proper. Care is
required while driving; it should not be damaged,
proper inspection can avoid the loss of fluid and
brake failure. [21]
In Disk brake; Braking Torque is important factor,
TB = FT.R
Where TB= Braking Torque
R= Radius of Rotor Disk
FT= Total normal force on disk brake
FTRI + FTRO
Normal force between pad and rotor
Inner plus Outer
Then Braking Distance (X) can be calculated as
Work done= FT.X
Where FT=FTRI+FTRO
And X = Distance travelled before vehicle stops.
We know Kinetic Energy of the vehicle
KE= KE=1/2 MV2
In order to bring vehicle at rest work done against
friction must be equal to kinetic energy of the
vehicle.
5.3 Failure in Master Cylinder:
A brake master cylinder is framed to be the
important component in a fluid braking system as
the pressure applied by the brake pedal is
transmitted to the brake fluid lines through the
master cylinder. Some of the symptoms of a master
cylinder failure are as : Improper behavior of brake
pedal, Master Cylinder Sensor indication in cabin,
Brake fluid contamination.
 International Journal of Engineering Technology Science and Research
Fig - 4: Brake Master Cylinder
In a typical brake master cylinder, the reservoir is
generally of plastic and the plastic reservoir is
coupled with the metal part using grommets made
of rubber. Deterioration will also be a source of
failure in brake master cylinder. Some of the
sources of failure in master cylinder are: O-rings in
cylinder may get damage and leak fluid, Metal
Fluid lines to the master cylinder may rot and cause
fluid leak, Brake fluid pressure has to be set in the
right optimum level
6. CONCLUSION
The paper investigated the various modes of failure
in hydraulic braking system. The failure of brakes
can be avoided, if the mechanical component of
braking system works properly. The maintenance of
components can avoid the accidents. This is the
hardware part of the braking system. The modern
invention may provide the safety from modern
equipments but if the basic parts are synchronised
then the number of accidents can be reduced.
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1013 Anant W. Nemade, Samir A. Telang, Dr. Arvind L. Chel
IJETSR
www.ijetsr.com
ISSN 2394 – 3386
Volume 5, Issue 3
March 2018
of Road Transport & Highways 09- June- 2016
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 International Journal of Engineering Technology Science and Research
IJETSR
www.ijetsr.com
ISSN 2394 – 3386
Volume 5, Issue 3
March 2018

[19] Banthia P, Koirala B, Rauniyar A, Chaudhary D,
Kharel T and Khadka SB. (2006)An epidemiological
study of road traffic accident cases attending
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1014 Anant W. Nemade, Samir A. Telang, Dr. Arvind L. Chel