5/19/2015

Brakes

Definition
As a mechanical device, which is used to absorb the
energy possessed by a moving system or mechanism
by means of friction

TOPIC: BRAKES

Function
To slow down or completely stop the motion of the
moving system, e.g. rotating drum, machine, vehicle

5/19/2015

Brakes

Brakes Mechanical

Brake capacity depends on

Unit pressure between surfaces
Contacting area of braking surface
Radius of the brake drum
Coefficient of friction
Ability of brake to dissipate heat which is equivalent to
the energy being absorbed

Classification
Shape of frictional material
Block brakes
Internal or external brakes
Disc brakes
Band brakes
Direction of actuating force
Radial brakes
- Internal / external shoe brakes
Axial brakes
- Disc brakes

Classification
Mechanical
Hydraulic
Electric
5/19/2015

5/19/2015

5/19/2015

5/19/2015

Brakes Mechanical

Brakes Mechanical

Block Brake

Internal expanding brake

5/19/2015

Brakes Mechanical

5/19/2015

Brakes Mech Block Brake wt Short Shoe

Consists simple block pressed
against rotating drums by
lever

Friction between block and
drum causes retardation

Employed in railway trains

Block is either rigidly attached
or pivoted to the lever

Angle of contact less than 45o
to maintain uniform pressure

Band brake
5/19/2015

Disc brake

5/19/2015

5/19/2015

Brakes Mech Block Brake wt Short Shoe

Brakes Mech Block Brake wt Short Shoe

Assumptions

Braking torque

Block is rigidly attached to the lever

Small angle of contact - uniform pressure distribution
Brake drum is rotating in clockwise direction

Mt = N R

Eq. to determine dimensions of block

Notations
Mt
R

N
p
l
w
c

braking torque (applied in anticlockwise), N-mm

radius of brake drum, mm
coefficient of friction
normal reaction, N
permissible pressure betn block and drum, N/mm2
length of block, mm
width of the block, mm
location of hinge pin w.r.t. block

5/19/2015

Brakes Mech Block Brake wt Short Shoe

Width
Optimum range

1
1
(Drum dia.) < w < (Drum dia.)
4
2
5/19/2015

10

Brakes Mech Block Brake wt Short Shoe

Width
Width is small
Length of block increase and size of brake
increase
Hence, narrower block results in unnecessarily
large size brake
Width is more
Makes difficult to maintain uniform pressure across
complete surface of friction lining
Hence, wider block results variation in normal
pressure distribution

5/19/2015

N = plw

11

Horizontal and vertical reactions

Rx = N

R y = (N - P)

Actuating force on lever (P)

(a c)
P=
N
b

a = c
a < c
5/19/2015






a > c

 Moments due to braking effort

(P x b) & Friction force (N x c)
both anticlockwise
 N helps to reduce P
 Called Self-energizing brake

P = 0, no external force required

Called Self locking brake
Not desirable in normal applications
Some positive force P should be required

 Negative P
 Uncontrolled braking and grabbing
12

5/19/2015

Brakes Mech Block Brake wt Short Shoe

Brakes Mech Block Brake wt Short Shoe

Conclusions
1. Block brake should be designed such that
it should not be self-locking
full advantage of the partial self-energizing is
possible
Condition a > c
2. To avoid brake arm from grabbing, the moment of
friction force about pivot (Nc) should be less than
the moment of brake effort about pivot (Pb)

5/19/2015

13

Brakes Mech Block Brake wt Short Shoe

Conclusions
3. Drum rotation is assumed anti-clockwise,

( a + c)
P=
N
b
 Braking effort (P) depends on
direction of rotation of brake drum
 P is more for anticlockwise rotation
 brakes are designed to have small
values of braking effort

5/19/2015

14

Brakes Mech Block Brake wt Long Shoe

Conclusions
4. Self-energizing action depends upon
Location of pivot for brake lever(a) / brake arm(c)
Coefficient of friction ()
Direction of rotation of brake drum

Disadvantage
Tendency of brake drum
shaft to bend under the
action of normal reaction
Can be resolved by using
symmetrical blocks on
opposite sides

Length of block is long, consequently angle of contact is

more and greater than 450

5/19/2015

5/19/2015

15

Equivalent Coefficient of Friction

4 sin
' =

2 + sin (2 )

Consider in place of and design a block brake using
same equation specified for block brake with short shoe.

16

5/19/2015

Brakes Capacity Based on Energy Absorbed

Brakes Capacity Based on Energy Absorbed

When a body of mass m (kg) retarded from its initial

velocity (V1 m/s) to its final velocity (V2 m/s), then kinetic
energy absorbed by brake (J) is

When mass m (kg) falling through a height h (m) then

potential energy absorbed by brake (J) is

1
2
2
KE = m V1 V2
2

Mass, kg

Mass moment of inertia,

kg-m2

Radius of gyration, m

Similarly, for rotating body

1
2
2
KE = I 1 2
2
=

1
2
2
mk 2 1 2
2

PE = mgh

Depending on the type of application, the total energy
(E) absorbed by brake can is determined by adding all
types of energies involved

Then

Total energy = Work done by brake

1 Initial angular velocity,

rad/s

E = M t

2 Final angular velocity,

rad/s

5/19/2015

17

Brakes Mech Internal Expanding

Mt

Braking torque, N-m

Angle through which brake

drum rotates during
braking period, rad

5/19/2015

18

Brakes Mech Internal Expanding

Used in vehicles, conveyors, hoist

Consist of shoe, drum, friction lining, actuating force
assembly

Advantages
Simple construction with small number of parts
Cheaper as compared with other types of breaks
More reliable due to small number of parts
Requires little maintenance
Small actuating force can produce large breaking
torque
Offers protection against entry of foreign particles.

Disadvantages
Poor heat dissipating capacity
Self lock possibility due to wear

5/19/2015

5/19/2015

19

20

5/19/2015

Brakes Mech Internal Expanding

Brakes Mech Internal Expanding

Assumptions
Intensity of friction lining and brake drum at any point
is proportional to its vertical distance from the pivot.
Brake drum and the shoe are rigid
Centrifugal force acting in the drum is negligible
Coefficient of friction is constant
Drum rotation is assumed clockwise.

R
w
1, 1,
1
2
h
C
p

pmax
5/19/2015

21

Brakes Mech Internal Expanding

5/19/2015

22

Brakes Mech Internal Expanding

Single shoe

5/19/2015

Coefficient of friction
Radius of drum, mm
face width of friction lining, mm
are w.r.t. to the line joining center of drum and center
of pivot and subtended at center of drum
Angle at which friction material begins
Angle at which friction material ends
Location of pivot from axis of brake drum, mm
Dist. of actuating force from axis of shoe pivot, mm
Normal pressure on elemental area of friction lining
located at center angle from pivot and subtending
an angle d , N/mm2
Max intensity of pressure for friction lining, N/mm2

Forces on Internal Expanding Brake

23

5/19/2015

24

5/19/2015

Brakes Mech Internal Expanding

Brakes Mech Internal Expanding

Moment (Mf) due to frictional force (dN) about pivot

Mf =

Actuating force (P) {drum rotation is assumed clockwise}

p max Rw[4 R (cos 1 cos 2 ) h(cos 21 cos 2 2 )]

4sinmax

Moment (Mn) due to normal force (dN) about pivot

Mn =

P=

Mn - M f
C

If drum rotation is anti-clockwise then actuating force (P)

p max Rwh[2(1 2 ) h(sin 2 2 sin 21 )]

4sinmax

P=

Mn + M f
C

Elemental torque

Mt =

R 2 p max w(cos 1 cos 2 )

sinmax

5/19/2015

25

Brakes Mech Internal Expanding

5/19/2015

26

Brakes Mech Internal Expanding

Automotive type double shoe

Automotive type double shoe

Left hand shoe

Right hand shoe

P=

Mn - M f

P=

pmax

pmax= Max intensity of

pressure

Mn + Mf

C
C P p max
= p max

Mn + Mf

Torque absorbing capacity

M t = (M t )R + (M t )R =

5/19/2015

27

5/19/2015

R 2 w(cos 1 cos 2 )
[p max + pmax ]
sin max
28

5/19/2015

Brakes Mech Internal Expanding

Brakes Mech Internal Expanding

Sign conventions

Guidelines
Ergonomic consideration (design consideration):
Max force P
22 25 N

Vehicle moving forward- clockwise drum rotation

Vehicle moving reverse- anticlockwise drum rotation

Observations

Right foot capacity of

o Fifth percentile female
o Fifth percentile of male

Clockwise  Couple due to actuating force (P x C) and couple

due to friction force (Mf), both clockwise
 i.e. friction force helps to reduce actuating force
 This is Self energizing effect
Anti Couple due to actuating force (P x C) and couple
clockwise
due to friction force (Mf) are in opposite
 i.e. friction force tends to increase actuating force
 In-turn force on break pedal increases
Hence, breaking action in reverse motion is not as effective as
in forward motion
5/19/2015

29

Brakes Mech Band Brake

11 17 N

Safety
Should not be designed to obtain a deceleration of
1 g (= 9.81 N/m2), when vehicle is fully loaded
5/19/2015

30

Brakes Mech Band Brake Simple

Construction
Flexible steel strip lined with friction material, which is
pressed against rotating drum

Used in
Bucket conveyors,
hoists
chainsaws
1. Simple Band Brake
When one end of steel band
passes through fulcrum of
actuating lever
5/19/2015

Min force P
Max pedal travel < 150 mm

= 22 N
= 25 N

31

Free body diagram & Notations

5/19/2015

P1

Tension on tight side of band, N

P2

Tension on tight loose of band, N

Coefficient of friction between

friction lining and brake drum

Angle of wrap, rad

Mt

Torque capacity of the brake

Radius of brake drum, mm

Distance of band connection

from fulcrum, mm

Lever arm, mm

Width of steel belt, mm

32

5/19/2015

Brakes Mech Band Brake Simple

Brakes Mech Band Brake Simple

Ratio of band tensions

Intensity of pressure

P1
= e
P2

p=

Torque capacity of brake / torque absorbed by brake

P
Rw

Intensity of pressure is Max, when P = P1

M t = ( P1 P2 ) R

pmax =

P1
Rw

Force acting on lever / actuating force

P=

P2 a
l

5/19/2015

33

Brakes Mech Band Brake

Importance

When neither ends of the band passes through fulcrum of

the actuating lever
Mainly designed for self-locking condition

Actuating force

P2 a P2b
l
P2 (a be )
=
l

P=

5/19/2015

34

Brakes Mech Band Brake Differential

2. Differential Band Brake

Construction

5/19/2015

FBD

Criteria
for selflocking

a
e
b
35

Self-locking property is undesirable, as brake goes out of

the operators control
In short, the brakes are designed in such way that they
should require a small but positive force for its operation,
which can be applied externally as and when required
However, self-locking feature can be advantageous in
back stop mechanism, i.e. to restrict reverse rotation
Differential band brake works as back-stop brake for
reverse operation.
The brake indicated in previous diagram satisfies condition
for self locking for clockwise rotation of drum, hence
restricts clockwise rotation of drum
5/19/2015

36

5/19/2015

Brakes Mech Band Brake Differential

Brakes Mech Band Brake

Importance
Conversely, for anticlockwise rotation, belt gets loosen and
drum rotates freely
Popular in hoisting and material handling elevators
E.g.
In case of bucket elevators it prevents loaded buckets
from reversing their direction in case of power failure of
power shut off.

Advantages
Simple construction, small number of parts, hence
less cost
Easily producible, without any requirement of special
facilities
More reliable due to small number of parts
Requires little maintenance

Disadvantages
Poor heat dissipation capacity
Uneven wear of friction lining from one end to another

5/19/2015

37

Brakes Mech Disc Brake

 Constitutes

Disc

Calipers
 Annular sized two break
pads on either sides of disc
 Friction lining on each pad
 A caliper attached to a non-rotating member exerts force P on
each pad
 When the pads are pressed against the rotating disc, the friction
force between lining and disc retards the speed and finally stops
the disc
 Break pad occupies only small portion of disc, where heat is
generated due to the friction
 Contrary, complete surface of disc is available for dissipation of
heat
5/19/2015
39

5/19/2015

38

Brakes Mech Disc Brake

Characteristics
Since, caliper is used, it is also called as caliper disc
brakes
As axial force is applied on two disc pads, it cancels
each other and leaves no thrust load on bearings

Applications
Mostly find on the front wheel of motorcycles
Lift trucks
Farm machinery
Light mobile equipments
5/19/2015

40

10

5/19/2015

Brakes Mech Disc Brake

Brakes Mech Disc Brake

Advantages
Simple to install and service
High torque transmitting capacity in small volume
Inherent ability to dissipate heat, hence insensitive to
the changes of coefficient of friction and there is no
mechanical fade of friction lining.
Easy to control
Never becomes self-locking
Equally effective for both directions
Linearity i.e. breaking torque is linearly proportional to
the actuating torque

5/19/2015

41

Brakes Mech Disc Brake

Notations

Mt

Outer radius of pad, mm

Ri

Inner radius of pad, mm

Angular dimension of
pad, rad

Coefficient of friction

Actuating force, N

Area of pad, mm2

Torque capacity of the pad, N-mm

pavg Average pressure, N/mm2

Rf

Friction radius, mm

Mean radius of pad, mm

Dist. of brake pad center from

axis of disc, mm

5/19/2015

42

Brakes Mech Disc Brake

Assumptions
Area of pad is comparatively small, hence pressure
on friction lining is uniform
Two shapes of pad Annular, circular

Friction radius of Annular Pad for uniform pressure
3
3
2 R Ri
R f = o2

3 Ro Ri 2

Torque capacity of the Disc Brake

M t = PR f

Area of the pad

1
A = ( Ro2 Ri2 )
2

Actuating force P

Friction radius of Circular Pad

P = pavg A

Rf = e

5/19/2015

R0

43

5/19/2015

44

11

5/19/2015

Brakes Friction Materials & Temperature

Brakes Friction Materials & Temperature

Materials and Permissible Temperatures

Rise in temperature - Analytical Calculation

Rise in temperature (t) depends on
Mass on brake drum assembly (m kg)
Ratio of the breaking period to rest period
Specific heat of the material (J/kgoC)

Assumption
Total heat generated = Heat absobed by brake drum assembly

In preliminary design analysis - pv factor considered

At constant heat generated is proportional to (pv)

Rise in temperature (oC)

(p is intensity of pressure & v is rubbing speed)

t =

E
mc

E is total energy absorbed by the brake (J)

Gives rough approximation, but actual

temperature is always less due to heat losses
5/19/2015

45

5/19/2015

rise

in
46

12