Binek araçlarda kullanilan kampana fren sisteminin özelliklerinin i̇yileştirilmesi ve tasariminin geliştirilmesi

Owing to the developing technologies the safety features of automobiles have come to the forefront as the braking systems have vital roles since they are the most important safety equipment of the vehicles. Drum brakes used in passenger cars, commercial and heavy vehicles since now have been used in some passenger vehicles, commercial and heavy vehicles in the rear wheels. When the disc and drum brakes called friction brakes are examined, the rapid increase in heating due to braking in the drum, slow cooling, failure of the brake lining caused by the braking and excessive accumulation of dust are noted as the most common problems of the system. In this study, the importance of brake systems has been investigated and advantages and disadvantages of drum brake system are emphasized. The most widely known disadvantages are intended to be reduced and even turned into an advantage by developing the best design. It has been observed how this vital safety equipment has improved and the level of safety combined with driving comfort has been noted. First of all, brake system calculations were made to meet the target improvements. The 3D solid modelling of the improvements made according to these calculations was drawn with Solidworks 2017 computer aided CAD program and structural analyses were performed with Solidworks and Ansys 16.0 Workbench. The drum, one of the most important elements of the drum brake system, is designed to be air-cooled. Solid modelling was performed according to the original drum size to design the air-cooled drum. The design was re-dimensioned considering the thickness of solidification shrinkage and thickness of initial machining during the casting process. Taking into account the dimensions made, the model was produced from wood material and samples were made from spheroidal cast iron using the sand mold casting method. After casting, it was brought to basic dimensions with machining. The sample was mounted on a passenger car and tested on the Corghi BT90 Pro brand brake tester. Temperatures generated by friction were analyzed for normal drum and sample by using Solidworks and Ansys program and the data obtained from brake test were compared to Solidworks analysis results. The automatic adjustment mechanism used in drum brakes has been redesigned for more efficient operation and as a result of structural calculations, solid modelling has been drawn and structural analyses have been performed.