BRAKES BLOCK OR SHOE BRAKES Application of block brakes include the following: large stationary machines, large trucks and, locomotives, and railed vehicles and trains ‘They are usually installed with a pair of blocks or shoes for greater capacity, better stability and lesser bending moment on the shaft that is supporting the drum ‘They are also referred to as “drum brakes”, especially the internal expanding shoe brakes used by vehicles. In the presentation the contact angle at each block is symbolized by 28. If 20 < 45°, the brake is referred to as a short shoe brake, ie. no correction is necessary for the coefficient, of friction If 20 > 45°, the brake is known as a long shoe brake. ‘Analysis requires the use of Integration as suggested by textbooks ~ a long and tedious process. Use this for Tong shoe brakes with shoes that are fixed tothe brake arm (shoe is not pivoted against the brake arm) If 20 > 45°and the shoes or blocks are pivoted with respect to the arm, the shoes or blocks are assumed as self-centering and the midpoint of contact is taken as, the point of concentration of the normal and friction, forces (a simpler analysis). However, due to a large ‘contact angle, the coefficient of friction is corrected as: f= thea sinz ae (always > 1) Coefficient of friction from tables, charts, etc. (as tested) Corrected coefficient of friction Machine Design 2 1Sem 2023-2024 BASAEN.RV_ % ‘Typical Setup for a Double-block Brake RoR Brake Bake drum Brake block o shoe Analysis of a Single-block Brake © Drum rotates clockwise From the FBD of the brake drum, [M, = 0] rar(2) =a D Where P= normal force between drum and block F = frictional force developed 40T= friction torque or torque absorbed by the brake Relationship Between F and P For a straight contact surface, Direction of motion > Straight contact surface EN or fP or Curved contact surface P FafPp: fof Asind 20 + si F=Pf 5 +) From the FBD of the brake arm, [2M, = 0] Ra +c) + Fle) = Pla) Pa) ~ Fe) R= SS = (8) (Braking force necessary) * Drum rotates counterclockwise Equations (1) and (2) remain unchanged, but equation (3) is changed 10, P(a) + Fle) ware 78) Note: From the given setup, the brake is selene in a clockwise drum rotation (lesser R is required). Pressure developed at the block or shoe (I pressure, p) Machine Design 2 1Sem 2023-2024 BASAEN.RV $% Where b= block or shoe width D. = brake drum diameter 28 = contact angle between block and drum Note ‘This pressure should not exceed the limiting pressure value (Pinus) of the brake lining material Friction Power: The power absorbed by the brake is equal to the torque T multiplied by the angular speed of the drum at the instant of braking Power = T(m) Note Block brakes are typically assembled using two blocks for greater capacity and stability. (i.e. lesser bending on the shaft supporting the drum). Thus, the friction force is developed at both blocks and the total friction torque is: D T= +P z Where F, = friction force developed at the left block Fy = friction force developed at the right block R= Braking force applied at the ‘operating lever (usually a spring force S in some set-ups) friction torque D Right book Left bck 41Example Determine the braking force R requited to absorb 5 KW at 300 rpm from the single-block brake set-up given. Use a ‘coefficient of friction of 0.30, a contact angle of 9°, and a block width of 100 mm. Solve using a) CW drum rotation, and b) CCW drum rolation. Also determine the pressure developed at the block. Dimensions are in ma, Solution: a) CW drum rotation: R, p=? ‘% Machine Design 21" Sem 2023-2024 BASAEN. RV 4 b) CCW drum rotation: R, p=? Example 2: Determine the friction horsepower of the double- block brake arranged as shown if the braking force applied is $ = 150 Ib. Each of the blocks has a contact angle of 90° and a coefficient of friction of 0.25. Use an angular speed of 600 rpm and consider a block width of 4” at each block. Solve using: (a) CW drum rotation, and (b) CCW drum rotation. (c) Also compute the maximum lining pressure in part (a) Doubleblock brake assembly with pivoted blocks or sho, 2« * z a : scl we U(E 7 oO ie Solution: (@) Friction power=? : CW drum rotation ‘9X Machine Design 2 __1"'Sem 2023-2024 __BASAEN.RV_ 9% 8Machine Design 21" Som 2073-2024 BASAEN. RV 4 Example 3: Determine the minimum braking force necessary 10 absorb a torque of 667 ft-lb from the double block brake assembly as shown, Use a coefficient of friction of 0.3 & a contact angle of 120° for each block. The blocks are controlled by chains, atached to the sprocket, through an ‘operating lever which is rigidly fastened to the sprocket. Also specify the direction of drum rotation to attain this ‘minimum braking force. Use a width of 4” for each of the left and right blocks. As an additional requirement, ‘compute the maximum lining pressure (b) Friction power =? CCW drum rotation Solution: (©) Maximum lining pressure, Pas =? 449 Machine Design 2 _1*Sem 2003-2004 _BASAEN.RV_% 45DESIGN CONSIDERATIONS FOR BLOCK, BRAKES Reference: Machine Design by Black and Adams The following recommendations are based on a cast iron brake drum and block lined with asbestos. New lining materials (molded compounds, etc)are expected to operate similarly, but with slight difference in propentes (f, pv value, ete.) © Recommended po Value (Pressure — Velocity Product) pv = 30,000— 80,000 Ib Te used for intermittent operation in a well- ventilated surrounding used for continuous ‘operation in a closed. surrounding Contact pressure, p: For a single-block brake: eee a P= Dosing "P* Note: For a double block assembly, the average pressure may be used fora simpler calculation, Pave _ Pit Pe P= Dpsind = ZDbsino) “P* Rubbing Velocity, » Dn, [pm ‘© Recommended Block or Shoe Width to Drum Diameter Ratio (b/D) Recommended range is: baa Diaz °K Machine Desisn21*Sem 2003-2004 _Basamney Note: I bD< 1/4, the block becomes too narrow that it might not be held in good alignment against the drum (unequal wear ofthe block across the face) If bD >1/2, the block becomes too wide and cooling of the block is not uniform (results in uneven, cooling; center of the block deteriorates faster) Assessment for Block Brake Design: Designing a block brake often requires a cut and try solution, ie. the drum diameter is often being assumed and other requirements are checked until satisfactory results are met Example 4: A double-block brake is to be designed for a certain machine that runs at 600 rpm. A torque of about 175 ft — Ib isto be absorbed. The brake blocks are to be identical, with 0.3 coefficient of friction and 120° contact angle for each. From the expected operation of the brake, a pv of 50,000 Relbimin-in® is found to be sufficient. The given sketch shows the possible locations of the blocks with respect to the drum, Larger dimensions are not allowed due to space constraints Initial assessment suggests. the following from the setup (designer's discretion) a=6" 20 po = 50 000-0 ala =i a) Design the brake by specifying the drum diameter ‘D’ and the block width‘b’ required, 'b) Compute the braking force $ nevessary 10 absorb the torque, Solution: a) D,b- 46X Machine Design ?_1Som 2023-2074 BASAEN. RV % ANALYSIS OF HOE BRAI Conditions: 1. The shoe or block is not pivoted against the brake arm ‘The point of concentration of the normal and frictional forces in the block is. not necessarily atthe midpoint of contact 2. The contact angle exceeds the limit for short shoe analysis (02 ~ 8) > 45° Solution requires the use of lategration a long and tedious process but with more acceptable and reliable results. Analysis can be shortened withthe use of derived formulas for the necessary forces and moments Baake dean Note As shown, the brake is self-energizing ina CCW drum rotation, 47Dimensions: a= radial distance between the center of drum and the pivot support ‘o” 5 = drum radius 1 = momentarm ofthe actuating force R from the pivot support ‘o" b= Block or shoe width R= braking force (2-0) contact angle Moments and Forces in their Differential Quantities: Ditters clement of | sont of vith jesse From the const presep pate apmpaae burda = (riod dP = p(brd@) + (1): [Normal Force] Also, dk = faP Then, dF = pfbrad (2): (Friction Force) Taking moment summation at the center, (EM, = 0], ar = (aF)r = (pfbraeyr AT = (pfbr2d®) > (3): [Friction Torque] The pressure p is proportional to the moment arm of dP from pivot point “O° p«a(sind) But ais constant, hence, p « sin6, or P__ Pax Sin ~ SINBypax Thus, the pressure at any point “A” on the shoe or block, expressed in terms of the maximum permissible pressure, is — Pas P Sina [Pressure at any point on the shoe] (sino) > (4) Machine Design 2 1Sem 2023-2024 BASAEN.RV $% Note: If exceeds 90”, the contact pressure component becomes smaller and smaller. Thus, Gnax is the smaller of 8,and 90° (usually Bras = 90°) © Friction Torque, T Substituting eqn. (4) into eqn. (3), Pax a, ar = Pr (sino)(for?a) = Pm Foy2(sino)ao = SiO max Pee por? [sin Sings” f, ae) aa 2(cos0, — cos = SinB ag! P™ (E0801 ~ £0802) Moments of dPand dF with respect to the pivot point ‘0° F~afcosd) wae alsin) acsina) dMp = dP(sin8) Pine sino) (brdo)(asint a = (ERE snd rayon Mp = Pat—bra f sin? oda But Then, a Pras ppg f° se = aa fA ora Pmax fa Mp = sprig bra | (02 ~ 03) 1 + g(sin20, — sin20,)| 48Moment due to dF dM, = dF (x — acos®) = (<2 am, = (

are applied as shown and the shoes pivot at points O; and Op. The width of the brake lining is 35 mm, with a coefficient of friction of 0.4. The maximum intensity of lining pressure 0.4 MPa, (a) Determine the friction torque 7 and the magnitude of the forces Fy and Fz for maximum operating condition, wherein the actuating forces may not be equal (b) If F)-Fa, determine the maximum friction torque without exceeding the limiting pressure of 0.4 MPa. (©) If the shoes are to be arranged to make them self energizing at the given rotation, determine the torque capacity of this brake, both in in CCW and CW directions. Dimensions in ram Solution: (a) T,Fiand F: (Max. operating conditions) sl°K Machine Desisn21*Sem 2003-2004 _Basamney ® IfR-B.T (©) Tand F if both shoes are self-energizing, or self deenergizing. 2C. BAND AND BLOCK BRAKE 1 blocks Aeaualy sped along the band) band he F; + Fycos0 F, —F,)cos®: friction force F,sin0 + Fjsind = N N= (F; +F))sin®: normal force 4X Machine sign 2_1"Sem2073-2074 BASAEN. RV $% wpe Fe _ P= Fideos0 “P= > GSR psind Or, F, — F, = (ftan6)(F; + F)) F,(1 ~ ftan®) = F,(1 + Ftan®) Fy _ 1+ ftano FT ftand For the adjacent block: Fy _ 1+ ftané RY 1=ftand ‘Thus, considering all the blocks: p + ftandy" F, (t= feand Where F, = tight side tension of band Fz © slack side tension of band n= no, of blocks Example §: ‘Compare the band tension ratio between the following brakes: a) Band brake with a contact angle of 180° and P03 b)_ Band and block brake with f=0.3 and using 1 blocks whose contact angle is 15° for each block Solution: 3D. DISK BRAKE Friction Toque in a Brake: T =2F(r.) radius of the dise Friction force developed (F= Pf) 2 friction surfaces (one at each side ofthe disc) Friction torque Where For New Friction Surfaces, based on the Uniform Pressure Method (UPM) 1[D?- a = a 3|D For Old or Worn Friction Surfaces, based on the Uniform Wear Method (UPM) 1 r= 4O+d D_ = Large diameter ofthe friction surface of the dise d= small diameter ofthe friction surface of the dise Note If the problem specifies the equivalent radius at which the friction pads are concentrated, take this to be the friction radius 7, Machine Design 21" Som 2073-2024 BASAEN. RV 4 Example 9: ‘A disk brake uses a double-aliper as shown below, Four 70 rmm-diameter round pads are installed, wo on each side of the disk. These pads are located ata diameter of 260mm, The outside ameter ofthe disk is about 340 mm. The pads are made of a friction material having a coeflcient of friction of 03 and a limiting average pressure of about 0.52 MPa. Determine the Following (2) Clamping force on each side of the disk that must be provided to develop the limiting pad pressure. (b) Maximum brake torque that can be obtained (6) Solve (b) if the fiction radius is to be based on the ‘uniform wear method. 4 brake ps: Solution: (a) P=? Clamping force at each side of the disk ) T=? (©) T=? (Using a slightly greater friction radius from uPM) 4ENERGY ABSORBED BY A BRAKE a. Translational kinetic energy AKE = intod -vi) (linear kinetic energy) b. Rotational kinetic energy AKE,ocationat = Fln(@5 — 04) (rotational kinetic energy) ‘mass moment of inertia Ty = ke m_~ mass of rotating body k= radius of gyration of the mass initial, final angular In velocities Potential energy APE =mg(Az): — canbe+or - (potential energy) ‘Az = change of altitude of the body of mass m Note: The energy to be absorbed by a brake is the algebraic sum of all the applicable enerzy quantities above. ‘This energy is converted to frictional energy (Cheat) and is then dissipated to the surrounding Uy = [AKE + ARE carious + APE Also, UY, = m,C,(A0) —_— of the brake ¢p of brake material = 195 for aluminum Absorption Rate of Brakes: (Mp/in’) Frictional hp per in? of Surface Area of Brake Ur Sh? = ine of braking Recommended Values The following values are based on the recommendation from DME, by Spotts, They may serve as a guide in designing brakes. 9 Machine Design 2 _1*Sem 2003-2004 _BASAEN.RV_% For Industrial Services, fhptin? < 1 For Automotive Services, thplin® = 1,5 102.5 Note: The surface area (SA) is the rubbing surface arca of the brake drum or disk Example 10; ‘A brake is to absorb energy from a 3000 Ib car moving at 60 mph (88 fs), decelerating the car by 20 fs? until stop. Installed brakes are 4 disks with the given dimensions below, indicating the friction surface Each steel disk weighs 11.15 Ib Determine the following: (@)_ Energy to be absorbed by the brake ifthe car is, travelling in a level road (from 60 mph to stop) (6) ‘The same as (a), except that the car travels downhill at Az~ 30 ft (©) Final temperature of the disks if ther initial temperature drum if t; = 100°F 1) Absorption rate in p/n? (average) eak absorption rate in fhpvin® during the first second of braking, Note: Items (c),(d),(e) based on energy absorbed in (b), ie. based on a car travelling downhill. Solution: G@ Uy, energy to be absorbed by the brake: (®) Up, energy to be absorbed by the brake (downhill ariving) 35(©) Final temperature, tp =2: (based on the energy (a) Frictional hp per in? (average rate only) (©) Frictional hp per in? (peak rate; during the 1" second 56