Mechanical Brakes

Subject: Machine Design

Code:MEC503
Prof. Nilotpal Banerjee
Introduction
• A brake is defined as a machine element used to control the
motion by absorbing kinetic energy of a moving body or by
absorbing potential energy of the objects being lowered by
hoists, elevators, etc.
• The absorbed energy appears as heat energy which is
transferred to cooling fluid such as water or surrounding air.
• The difference between a clutch and a brake is that whereas
in the former both the members to be engaged are in
motion, the brake connects a moving member to a
stationary member.
Professor Nilotpal Banerjee, Department of Mechanical
16 October 2020 2
Engineering, NIT Durgapur
Types of Brakes
• Depending upon the direction of application of braking force, the
mechanical brakes are primarily of three types:
• Band brakes – braking force applied tangentially.
• Shoe or block brakes – braking force applied radially
• Disc brake – braking force applied axially.

Professor Nilotpal Banerjee, Department of Mechanical

16 October 2020 3
Engineering, NIT Durgapur
Band Brakes
A band brake consists of a band, generally made of metal, and embracing a
part of the circumference of the drum. The braking action is obtained by
tightenting the band. The difference in the tensions at each end of the
band determines the torque capacity.
Simple band brakes: When one end of the band is connected to the fixed
fulcrum, then the band brake is called simple band brake.
Differential Band Brakes: When none of the ends of the band is
connected to any fulcrum, then the band brake is called differential band
brake.

Professor Nilotpal Banerjee, Department of Mechanical

16 October 2020 4
Engineering, NIT Durgapur
Simple Band Brake
Clockwise rotation of the drum Counter-clockwise rotation of the drum

Figure: 1(a) Figure: 1(b)

Professor Nilotpal Banerjee, Department of Mechanical
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Engineering, NIT Durgapur
Governing equations
From the theory of Belt drive the relation between tight side tension(T1) and slack
side tension(T2) can be obtained by force balance of all forces on a small element
of the band, = e (1)
Where, µ= Co-efficient of Friction and θ= Angle of Wrap or contact angle
Now, Torque, T=(T1 – T2) R (2)
And Braking force, F = T − T = = (3)
Again, F = T − T = T2e - T2 = T2(e -1)
and therefore T = (4)
( −1)
Where, R= Radius of the brake drum and D= Diameter of the drum
Considering the clockwise rotation of Drum for a simple band Brake as shown in
Fig. 1(a) equation the moments of the forces on the lever,
T × b = F × a which gives, F = T × (5)
From (4) and (5), F = × (6)
( −1)
Professor Nilotpal Banerjee, Department of Mechanical
16 October 2020 6
Engineering, NIT Durgapur
Governing equations….
Considering counter clockwise rotation of the drum from Fig. 1(b), the tensions T1
and T2 will exchange their places and for the same braking torque, a larger force F is
required to operate the brake.F = T ×
T 1
and Braking force, F = T − T = T1- 1 = T1(1 - )
×
and hence, T =
( −1)
Therefore, F = F × (7)
−1
From equation (6) and (7) it is clear that for all finite positive values of a, b, θ and µ
the value of F can not negative, therefore, these type brakes will not have any self –
energizing or self-locking properties.
Now, Thickness of the band, h=0.005D and width, = ⁄ ℎ
where =Allowable tensile stress

Professor Nilotpal Banerjee, Department of Mechanical

16 October 2020 7
Engineering, NIT Durgapur
 Differential band brake
In differential band brake the two ends
of the band are attached to pins on the
lever at a distance of b1 and b2 from
the pivot pin as shown in figure. It is to
be noted that when b2 > b1, the force F
must act upwards in order to apply the
brake. When b2 < b1, the force F must
act downwards to apply the brake.
For clockwise rotation of drum
considering moment about the Figure: 2
fulcrum,
× = × +"×#

Professor Nilotpal Banerjee, Department of Mechanical

16 October 2020 8
Engineering, NIT Durgapur
Differential band brake
∴ Te × b − T × b =F × a (8)
Again Breaking force, F = T − T = T2e - T2 = T2(e -1) (9)
Slack side tension, T =
( −1)
%
From (8), F = (10)
−1
For brake to be self locking, " ≤ 0
Therefore the condition of self-locking , b e ≤ b (11)
Proceeding similarly, for counter-clockwise rotation, the self-locking condition
becomes, b ≤ b e (12)
If = = then the brake is called two-way brake i.e it can be used effectively for
×( )
both way of rotation and F =
−1
Professor Nilotpal Banerjee, Department of Mechanical
16 October 2020 9
Engineering, NIT Durgapur
 Shoe or block brake

In a shoe brake the rotating drum is brought in contact with the shoe by suitable force.
The contacting surface of the shoe is coated with friction material. Different types of shoe
brakes are used, viz., single shoe brake, double shoe brake, internally expanding brake,
externally contracting brake. These have been shown in Figures below.

Single Shoe Brake double Shoe Brake

Professor Nilotpal Banerjee, Department of Mechanical
16 October 2020 10
Engineering, NIT Durgapur
Shoe or block brake

Internally Expanding Shoe Brake Externally Contracting Expanding Shoe Brake

Professor Nilotpal Banerjee, Department of Mechanical

16 October 2020 11
Engineering, NIT Durgapur
Short Block or shoe brake
A single-block brake is shown in fig. It
consists of a short shoe which may be
rigidly mounted or pivoted to a lever.
The block is pressed against the
rotating wheel by an effort “F” at one
end of the lever. The other end of the
lever is pivoted on a fixed fulcrum “O”.
When the brake is applied, the lever
and the block can be considered as
separate free body, which has been
shown aside. The angle of contact
between the block and the brake is
small, for its value for 45o-60o it is
assumed that the pressure intensity is
constant all over the contact and also
the normal reaction acts at the centre.

Professor Nilotpal Banerjee, Department of Mechanical

16 October 2020 12
Engineering, NIT Durgapur
Equations for Short Shoe Brake
When angle of contact, θ ≤ 45- the pressure intensity, “p” is
considered as constant. From the figure,
Torque, T=µNR (13)
Where, N= Normal Reaction, R= Radius of the Drum and µ= Co-efficient
of friction.
Now N= plw (14)
Where, p= pressure intensity, l= length of the block and w= width.
Note: < w< where D= Diameter of drum
.

Professor Nilotpal Banerjee, Department of Mechanical

16 October 2020 13
Engineering, NIT Durgapur
Equations…
From static equilibrium,
R 2 = μN
R 5 = N-F
F × b − N × a + μN × c = 0
% 8
=> F = ×N (15)
Now, a − μc may have values,
a − μc > 0 (16a)
Or a − μc ≤ 0 (16b)
For (16a), F is positive, moment due to friction force is helping moment
due to actuating force, called self-energizing.
For (16b), F is zero and negative, case of self-locking.

Professor Nilotpal Banerjee, Department of Mechanical

16 October 2020 14
Engineering, NIT Durgapur
Equations…
If for the same configuration the rotation becomes anticlockwise , from
equation (15)
F × b − N × a − μN × c = 0
) 8
=> F = × N, this means that the value of F is more in
anticlockwise rotation for this type of configuration compared to that
for clockwise rotation.
Further, for anticlockwise rotation the brake is never self-locking.
Therefore a brake which is not self-locking may act as self-locked brake
if the rotation reverses.
But if the configuration changes i.e if the lever is at the top of the drum
the result reverses.
Professor Nilotpal Banerjee, Department of Mechanical
16 October 2020 15
Engineering, NIT Durgapur
Long shoe brake
For a small block shoe the angle
subtended by the shoe at centre of the
drum is generally less than 45o. In such
cases the pressure intensity may be
assumed to be constant all along the
surface of contact and the normal force
(N) as well as the friction force (µN) are
concentrated at the centre of the shoe.
For long shoe brakes it not so. A long shoe
block brake as shown is having semi block
angle denoted by θ, a small element of
friction lining of angular dimension dφ at
an angular distance of φ from the centre
line of the drum is shown. Block Brake with long shoe

Professor Nilotpal Banerjee, Department of Mechanical

16 October 2020 16
Engineering, NIT Durgapur
Long shoe brake…
The normal reaction dN on the element is given
by,
dN = (Rdφ)b × p (16)
Where, b is the width of the brake shoe along
the axis of the drum and p is pressure intensity.
The force of friction on the element is given by,
μ × dN = μ × Rdφ b × p (17)
Therefore torque on small element,
dT = μ pbR dφ (18)
)
T = μbR >% pdφ (19)

Professor Nilotpal Banerjee, Department of Mechanical

16 October 2020 17
Engineering, NIT Durgapur
 Long shoe brake…
• It is assumed that the shape of the brake shoe will
conform to the shape of the drum after @wear takes
place and as a consequence the point Y will take
position of point Y.
• If AB is the wear in Y direction and AC is wear in
radial direction as shown in figure. Now, AB is
constant for every point and therefore,
DE
AB = = constant (20)
8-F G
• Radial wear (AC) is proportional to work done by
frictional force i.e product of frictional force and
rubbing velocity. We can assume that rubbing
velocity is same for all such points and
therefore,δr ∝ μdN, putting the value of dN from
equation (16), Wear on the friction lining
δr ∝ μRdφbp and hence, δr ∝ p (21)

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16 October 2020 18
Engineering, NIT Durgapur
Long shoe brake…
From equations (20) and (21),
K
= Constant (C1), and hence p = C cos φ (22)
8-F L
Where C1 is constant. Now, p= pmax when φ = 0 and therefore,
Pmax=C1 (23)
From equations (7) and (8), p = PQRS cos φ (24)
Putting this value in equation (16) we have,
dN = (Rdφ)bPQRS cos φ (25)
There are two components of dN, vertical component dNcos φ and horizontal component dNsin V,
due to symmetry horizontal components will cancel each other on both sides, only vertical
component remains.
Therefore,
) )
N = >% dN cos φ = >% (Rdφ)bpW 2 cos φ cos φ
)
∴ N = RbpW 2 >% cos φ dφ (26)

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16 October 2020 19
Engineering, NIT Durgapur
Long shoe brake…
Now,
) ) FYZ L )
>% cos φ dφ = >% 1 + cos 2φ dφ = φ+ (27)
%
From equation (26),
FYZ L )
[ = RbpW 2 φ+ = . RbpW 2 4θ + 2 sin 2θ (28)
%
From equation (19),
)
T = μRbpW 2 >% cos φ dφ = 2 μRbpW 2 sin θ (29)
From equation (28) and (29),
. FYZ
T = μNR )FYZ
= μ′NR (30)

. FYZ
Where, ]@ = μ , can be considered as equivalent co-efficient of
)FYZ
friction for long
shoe brake and the formula for short shoe brake can be used putting µ’
instead of µ in the same equation. Pressure distribution on brake

Professor Nilotpal Banerjee, Department of Mechanical

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Engineering, NIT Durgapur
Drum Brakes
Drum Brake Types:
• Rim types with internal expanding shoes
• Rim types with external contracting shoes
Internal expanding Shoe:
The rim type internal expanding shoe is widely used for braking systems in automobiles. The basic
approach applied for its analysis is known as long-rigid shoe brake analysis as discussed in last slide.
A schematic sketch of a single shoe located inside a rotating drum with relevant notations, is shown
in the figure. In this analysis, the following are assumed;
1) pressure at any point is assumed to be proportional to the vertical distance from the hinge pin,
which is proportional to sine of the angle and thus, p ∝ d sin θ ∝ sin θ. Since the distance d is
constant, the normal pressure at any point is proportional to sin θ. Say constant of
proportionality = K , therefore p = K sin θ
2) The shoes are rigid.
3) The coefficient of friction does not change with pressure.

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Engineering, NIT Durgapur
Drum Brakes
If the maximum allowable pressure for the
lining material is pW 2 then the constant K
can be defined as,
` K
_=
FYZ a
= FYZbcd
bcd

pW 2
p= sin θ
sin θW 2

The normal force dN is computed as the

product of pressure (wrdθ) and area and the
frictional force as the product of normal force
and friction coefficient (µdN).
By integrating these over the shoe length in
terms of its angle the braking torque T, and
other brake parameters are computed.
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16 October 2020 22
Engineering, NIT Durgapur
Drum Brakes
For actuating force F, the moment equilibrium about the pivot point is considered.
For this we need to determine the moment of the normal force (Mf ) and moment
of the frictional force (M ) about the pivot point.
Kbcd
Mf = > pwrdθ × d sin θ = > pwr d sin θ dθ = > wr d sin θ dθ
FYZ bcd
Kbcd
or, Mf = wrd> θ −θ − sin 2θ − sin 2θ (31)
FYZ bcd .

Kbcd a k
M => ]pwrdθ × C − i cos j = μwr >a C sin j − sin 2j dθ
FYZ bcd
Kbcd a k a
lC, mn = μwr C − cos j a − − cos 2j a
FYZ bcd .
Kbcd k
= μwr C cos j − cos j − cos 2j − cos 2j (32)
FYZ bcd .

Professor Nilotpal Banerjee, Department of Mechanical

16 October 2020 23
Engineering, NIT Durgapur
Drum Brakes
The actuating force F is determined by the summation of the moments of
normal and frictional forces about the hinge pin and equating it to zero.
Summing the moment about point “O” gives,
op ±or
F= (33)
where,
Mf and M are the moment of the normal and frictional forces respectively,
about the shoe pivot point. The sign depends upon the direction of drum
rotation, (- sign for self energizing and + sign for non self energizing shoe)

Professor Nilotpal Banerjee, Department of Mechanical

16 October 2020 24
Engineering, NIT Durgapur
Drum Brakes
The reaction forces are determined by applying force summation and
equilibrium,
a a a a
st =>a i[ cos j + >a ]i[ sin j = >a CP cos jij + >a ] CP sin jij
And (34)
a a a a
sv =->a i[ sin j − >a ]i[ cos j = − >a CP sin j ij − >a ] CP cos j ij
The braking torque T on the drum by the shoe is of the frictional forces μdN times
the radius of the drum(r) and resulting equation is,
Kbcd wx Kbcd
T=> μwr sin θdθ= cos θ − cos θ (35)
FYZ bcd FYZ bcd

Professor Nilotpal Banerjee, Department of Mechanical

16 October 2020 25
Engineering, NIT Durgapur
Double Shoe brakes
Two such shoes are combined into a complete practical brake unit, two being used
to cover maximum area and to minimize unbalanced forces on the drum, shaft and
bearings.

One leading shoe

Two Leading shoe
& one trailing

If both the shoes are arranged in such a way that both are leading /trailing shoes,
then all the other parameters remaining same the total braking torque on the
drum is twice the value of one.
Professor Nilotpal Banerjee, Department of Mechanical
16 October 2020 26
Engineering, NIT Durgapur
Double Shoe brakes

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16 October 2020 27
Engineering, NIT Durgapur
Double Shoe brakes
• However in most practical cases the shoes are arranged such that one is
leading and other is trailing for a given direction of drum rotation.
• If the direction of rotation of drum changes then the leading shoe will
become trailing and vice versa.
• Thus this type of arrangement will be equally effective for either direction
of drum rotation. Further the shoes can be operated upon using a single
cam. However the total braking torque will not be twice the value that of a
single shoe, if the same normal force is applied.
• The effective contact pressure (force) on the trailing shoe will not be the
same that of the leading shoe, as the moment of the friction force opposes
the normal force in the case.

Professor Nilotpal Banerjee, Department of Mechanical

16 October 2020 28
Engineering, NIT Durgapur
Double Shoe brakes
As the moment about the pivot is essentially proportional to pW 2 ,
or y Kbcd y op y Kbcd y
= and = (36)
or Kbcd op Kbcd
Where the quantities marked with prime(‘) corresponds to trailing side.
Now since force on both the shoes are same,
op ±or op y ±or y
F= = (37)
From the above relation pW 2 can be found.
zy Kbcd y
Similarly, = (38)
z Kbcd

Professor Nilotpal Banerjee, Department of Mechanical

16 October 2020 29
Engineering, NIT Durgapur
Disc Brake

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16 October 2020 30
Engineering, NIT Durgapur
 Disc Brake
• A disc Brake is similar to plate clutch, except that one of the shafts is replaced by a fixed member.
• The front wheel of almost all two wheelers and small four wheelers uses this type of brakes.
• It consists of a calliper which has two friction surfaces on both sides of a rotating disc attached to the axle of
the wheel and covers a small sector of the disc. The remaining part of the disc is used for dissipation of heat.
• No lubrication is required, it air cooled.
• The friction pads are in the form of annular sector and has lining with high coefficient of friction. When the
brake pads are pressed by the use of fluid pressure against the rotating disc the wheel retards down.
Schematic diagram of one such brake is shown.
Advantages:
1. Simple to install and service
2. High torque capacity in small volume
3. Never becomes self-locking
4. Equally effective for both direction of rotation

Professor Nilotpal Banerjee, Department of Mechanical

16 October 2020 31
Engineering, NIT Durgapur
Disc brake Equations
Assumption: Since the area of the pads are very small in comparison to that of the disc uniform
pressure theory is used.
-| % Y|
Torque=T = n = μF R } (39)
{ - % Y
Where, “n” is the numbers of pairs of friction surfaces and
•€| %••|
s~ ={ × • %• = Friction radius(mm)
€ •
a
Area of the Pads=A= ƒ s„ − s… (40)
‚
Again, F =p × A (41)

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16 October 2020 32
Engineering, NIT Durgapur
Heat considerations in Brakes
Rate of heat generated due to friction in brakes can be estimated by
the following equation,
Rate heat generation=H‡ = p ˆ A8 μV watt
Where,p ˆ = average contact pressure, N⁄m
A8 = Contact area, m
μ= coefficient of friction
V= Peripheral velocity of drum,m⁄s
Rate of heat generated can also be calculated as amount of KE and PE
which is being absorbed,
H‡ = EK + EŒ watt

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16 October 2020 33
Engineering, NIT Durgapur
Heat considerations in Brakes
Heat dissipated, H• =C ∆t Ax watt,
Where, C= Coefficient of heat transfer, W⁄m K
∆t= Temperature difference, K
Ax = Area of radiating surface, m
Use C=29.5 W⁄m K for ∆‘= 40 K and C= 44 W⁄m K for ∆‘= 200 K
Another convenient indicator of brake capacity is kW⁄wD and is
limited to 350 W⁄m ,
Where, w= width of the band or shoe (m)and D= diameter of drum (m)

Professor Nilotpal Banerjee, Department of Mechanical

16 October 2020 34
Engineering, NIT Durgapur