The air brake valve is widely used in automotive braking systems. Korea automobile industry depends on imports of the brake valve. Therefore, we should raise the technical expertise to develop brake valve domestically. In this study, air brake valves was analyzed which can be used in a variety of automobiles. Computational fluid dynamics analysis, static structural analysis, and hyper elastic analysis were carried out.

(1) Results of CFD analysis and prototypes tests were compared for the brake pedal angle, 11.6% average error at PP(Primary port) and 11.0% average error at SP(Secondary port) were found.
? Therefore, the reliability of the analysis is considered high. The mean square error for each measuring point values were shown below 0.2bar.

(2) The amount of compression of the O-ring used in the plunger relay was measured and compared with the results of hyper-elastic analysis which showed a 17.6% error. Expected error occurs because of the physical properties of the material, calculated on the basis of the tensile test results. The error can be reduced if material properties based on compression test are used in the analysis.

(3) If the pressure values exceeds the reference pressure, the brake valve is broken where the generation is expected to occur in the plate (A) in the valve, which is associated with the vehicle. The calculations predicted that the brake valve used in this study can withstand till 48 bar, while the burst pressure of 20 bar is recommended by the test standards. The relevant parts of the plunger relay shall not exceed 0.4 mm deformation. The current design is structurally stable, excessive safety factor (2.78) is assured.

Before production of air brake valve system, the performance of different parts was evaluated using finite element analysis. The structural stability of the product can be determined using static dynamics. Compression behavior of the O-ring can be predicted through nonlinear hyper elastic analysis, an error is possible due to one way loading. This simulation study can save time and reduce cost instead of developing experimental prototypes.