Author : Sourabh M. Dhole, V. V. Saidpatil and S. Y. Gajjal

Most of the two wheeler vehicles have disc brakes to their front wheel. The disc brake consists of master cylinder which is housing for a plunger which acts as a piston to create and push the pressurized oil into the oil hose of the front disc brake system. This piston is made of aluminum which is heavy in weight as compare to plastic. This project work focused on to change the material of the piston from aluminum to plastic so to reduce the piston weight. The locally manufactured aluminium piston was used for study purpose. To avoid measurement errors and to achieve close to accurate measurement of this piston, it was scanned and measured on machine. This scan data converted to CAD model and using FEA, stresses in Aluminum and Plastic has compared. The advantages of the changed material piston are the low cost and superior material properties. With above proposal we will get reduction in piston weight, design cost and productivity improvement due to material change of the piston from metal to plastic.

Keywords: Master cylinder piston, material change, plastic material, design and optimization

Article published in International Journal of Current Engineering and Technology, Vol.6, No.5 (Oct-2016)