23

BRAKES
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 obsorbed energy appears as heat energy which should be 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.

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 Fat one end of the
lever. The other end of the lever is pivoted on a fixed fulcrum O. The friclional force produced by
the block on the wheel will retard the rotation of the wheel. This type of brake is commonly used in
railway trains. When the brake is applied, the lever with the block can be considered as a free body
in equilibrium under the action of the following forces.

1. Applied force F at the end of the lever.

2. Normal reaction Fn between the shoe and the wheel.
3. Frictional or tangential braking force Fθ between the shoe and the wheel.
4. Pin reaction.

Let F = Operating force

M1 = Torque on the wheel
r = Radius of the wheel
2θ = Angle of contact surface of the block
µ = Coefficient of friction
M
Fθ = Tangential braking force = t
r
Fθ
Fn = Normal force =
µ
a = Distance between the fulcrum pin and the center of the shoe
b = Distance between the center of the shoe to the end of lever where the
effort is applied
c = Distance between the fulcrum pin and the line of action of Fg

Consider the following three cases;

(i) Line of action of tangential force F0 passes through fulcrum

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Taking moments about O,

Fθ ª Fθ º
F (a + b) = Fn a = a « Fn µ »
µ ¬ ¼

Fθ a
∴Actuating force F =
µ (a + b)

In this case the actuating force is the same whether the direction of tangential force is towards or
away from the fulcrum.

(ii) Line of action of tangential force Fθ is in between the center of the drum and the fulcrum
(a) Direction of Fθ is towards the fulcurm :

Taking moments about O,

F (a + b) = Fn c = Fn a

Fθ a ª Fθ º
F (a + b) = Fn a − Fθ c = − Fθ c « Fn µ »
µ ¬ ¼

Fθ a ª1 cº
∴Actuating force F = «µ − a»
( a + b) ¬ ¼

(b) Direction of Fθ is away from the fulcrum :

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Taking moments about O,

Fθ ª Fθ º
F (a + b) = Fn a − Fθ c = a + Fθ c « Fn µ »
µ ¬ ¼

Fθ a ª1 cº
∴Actuating force F = «µ − a»
( a + b) ¬ ¼

(iii) Line of action of tangential force Fθ is above the center of the drum and the fulcrum:

(a) Direction of Fθ is towards the fulcrum :

Taking moments about O,

Fθ a ª Fθ º
F (a + b) = Fn a − Fθ c = + Fθ c « Fn µ »
µ ¬ ¼

Fθ a ª 1 c º
∴Actuating force F = −
(a + b) «¬ µ a »¼

(b) Direction of Fθ is away from the fulcrum :

Taking moments about O,

Fθ a ª Fθ º
F (a + b) + Fθ c = Fθ a = a « Fn µ »
µ ¬ ¼

Fθ a
F ( a + b) = − Fθ c
µ
Fθ a ª 1 c º
∴Actuating force F = −
(a + b) «¬ µ a »¼
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Note: If the direction of F0 is towards the fulcrum, use the clockwise rotation formula and if
the direction of F& is away from the fulcrum, use counter clockwise formula from the
data handbook.

When the angle of contact between the block and the wheel is less than 60°, we assume that the
normal pressure is uniform between them. But when the angle of contact 2θ is more than 60°,
we assume that the unit pressure normal to the surface of contact is less at the ends than at the
center and the wear in the direction of applied force is uniform. In such case we employ the
equivalent coefficient of friction µ', which is given by.

4 sin θ
Equivalent coefficient of friction µ 1 = µ ×
2θ +sin 2θ

Where µ = Actual coefficient of friction

θ = Semi block angle

4 sin θ
For the given value of θ. The value of can be found by using the chart given in
2θ +sin 2θ

The brake is self -energizing when the friction force helps to apply the brake. If this effect is
great enough to apply the brake with zero external force, the brake is called self-locking i.e.,
the brake is self locking when the applied force F is zero or negative.

Normal load Fn
Normal pressure on the shoe p P = =
Pr ojected area of shoe 2wr sin θ

Where w = Width of the shoe

Example: The block type hand brake shown in fig. 3.1 la has a face width of 45 mm. The friction
material permits a maximum pressure of 0.6 MPa and a coefficient of friction of 0.24. Determine;
1. Effort F, 2. Maximum torque, 3. Heat generated if the speed of the drum is 100 rpm and the
brake is applied for 5 sec. at full capacity to bring the shaft to stop.

Data: w = 45 mm, p = 0.6 MPa = 0.6 N/mm2, µ = 0.24, 2θ = 90°, θ = 45e, d = 300 mm,
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r = 150 mm, n = 100 rpm

Solution:

4 sin θ
Since 2θ > 60°, equivalent coefficient of friction µ 1 = µ ×
2θ +sin 2θ

4 sin 45
= 0.24 × = 0.264
90 × π
+ sin 90
180

Fn
Allowable pressure p =
2 wr sin θ

Fn
i.e., 0.6 =
2 × 45 ×150 sin 45
∴Normal force Fn = 5727.56 N

Tangential force Fθ = µ' Fn = 0.264 x 5727.56 = 1512.1 N

The various forces acting on the shoe are shown in fig. 3.11b.
From the figure, a = 200 mm, b = 300 mm, c = 0
The tangential force Fθ, passes through the fulcurm.

Fθ a
∴Effort F =
µ ' (a + b)

1512.1 × 200
= = 2291.1 N
0.264 (200 + 300)

Torque on the drum M1 = Fθ r = 1512.1 x 150 = 226815 N-mm = 226.815 N-m

M 1 n 226.815 × 100
Power absorbed N = = = 2.375 kW = 2.375 kJ / sec
9550 9550

Heat generated during 5 sec = 5 x 2.375 = 11.875 kJ

Example:
A 400 mm radius brake drum contacts a single shoe as shown in fjg.3.12a, and sustains 200 N-m
torque at 500 rpm. For a coefficient of friction 0.25, determine:

1. Normal force on the shoe.

2. Required force F to apply the brake for clockwise rotation.
3. Required force F to apply the brake for counter clockwise rotation.
4. The dimension c required to make the brake self-locking, assuming the other dimensions
remains the same.
5. Heat generated.
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Data; r = 400 mm, M1- 200 N-m = 200 x 103 N-mm, n = 500 rpm, µ=0.25,
a = 350 mm, i = 1000 mm, b = l - a = 1000 - 350 = 650 mm, c = 40 mm

Solution:

M 1 200 × 10 3
Tangential friction force Fθ = = = 500 N
r 400

Fθ 500
Normal force on the Fθ = = = 2000 N
µ 0.25

From the figure, the tangential force Fθ lies between the fulcrum and the center of drum.. When the
force Fθ acts towards the fulcrum (clockwise rotation),

F0 a ª 1 cº
Actuating force Fθ = « − »
a +b ¬µ a¼

500× 350 ª 1 40 º
= = − = 680 N
350+ 650 «¬ 0.25 350»¼

For anticlockwise rotation of the drum, the tangential force Fs acts away from the fulcrum as
shown in figure.

F0 a ª 1 cº
∴Actuating force Fθ = « + »
a +b ¬µ a¼

500× 350 ª 1 40 º
= =« + » = 720 N
350+ 650 ¬ 0.25 350¼

When the drum rotates in clockwise direction, self locking will occur. For self locking effort
F ≤ 0.
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F0 a ª 1 cº c 1 a
i.e., = « − »≤0 or ≥ , c≥
a+b ¬µ a¼ a µ µ

350
∴ c≥ ≥ 1200 mm
0.25

Heat generated H g = µ p Ac v = Fn v

π × 800 × 500
= 0.25 × 2000 × =1071.98 W
60 × 1000

= 10.472 kW = 10.472 kJ / s

Example: The layout of a brake to be rated at 250 N-m at 600 rpm is shown in figure. The drum
diameter is 200 mm and the angle of contact of each shoe is 120°. The coefficient of friction may be
assumed as 0.3 Determine.

1. Spring force F required to set the brake.

2. Width of the shoe if the value of pv is 2 N-m/mm2-sec

Data: Mt = 250 N-m = 250 x 103 N-mm, n = 600 rpm, d = 200 mm, r = 100 mm,
2θ =120°, 0=60°, µ = 0.3, pv = 2 N-m/mm2-sec
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Solution:
4Sinθ
Since 26 > 60°, equivalent coefficient of friction µ' = µ ×
2θ + Sin2θ

Sin 60
= 0.3 × = 0.351
120 + π
+ sin 120
180
The various forces acting on the shoes are shown in figure.

Left hand shoe:

100
For left hand shoe, a = 150 mm, b = 150 mm, c = 100 − = 50 mm
2

The tangential force Fθ1 lies above the center of the drum and fulcrum, and acting away from
the fulcrum (counter clockwise).
F01 a ª 1 c º
∴ Spring force F = −
a + b «¬ µ a »¼

F01 × 150 ª 1 50 º
F = −
«
150 + 150 ¬ 0.351 150 »¼

∴Tangential force Fgi= 0.795 F

Right hand shoe:

The tangential force Fθ2 lies below the center of the drum and the fulcrum, and acting towards
the fulcrum (clockwise).

F02 a ª 1 c º
∴ Spring force F = −
a + b «¬ µ a »¼

F02 × 150 ª 1 50 º
F = −
150 + 150 ¬ 0.351 150 »¼
«

∴Tangential force F02 = 0.6285 F

Torque M 1 = ( F01 + F01 ) r

i.e., 250 × 10 3 = (0.795 F + 0.6285 F ) × 100

∴Spring force F = 1756.2 N

The maximum load occurs on left hand shoe.

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∴Tangential force F01 = 0.795 x 1756.2 = 1396.2 N

F01 1396 .2
Normal force on left hand shoe F01 = = = 3977 .8 N
µ 0.351

π dn π × 200 × 600
Surface velocity of drum v = = = 6 .283 m / sec
60 × 1000 60 × 1000

By data pv = 2 N-m/mm2 – sec

2 2
∴ Normal pressure p = = = 0.3183 N / mm 2
v 6.283

Fn1
Also pressure p =
2 wr sin θ

3977 .8
1.e., 0.3183 =
2 wr × 100 sin 60

∴ Width of the shoe w = 72.15mm