Addis Ababa Science & Technology University

College of Electrical and Mechanical

Engineering
Department of Electromechanical Engineering
Design of Machine Elements-II
By: Birhanemeskel A. (MSc in Mechatronics)
 Chapter-Three
Brakes
➢ A brake is defined as a mechanical device, which is used to absorb the
energy possessed by a moving system or mechanism by means of friction.
➢ The primary purpose of the brake is to slow down or completely stop the
motion of a moving system, such as a rotating drum, machine or vehicle.
➢ It is also used to hold the parts of the system in position at rest.
➢ An automobile brake is used either to reduce the speed of the car or to
bring it to rest. It is also used to keep the car stationary on the downhill
road.
➢ The energy absorbed by the brake can be either kinetic or potential or
both.

➢ In automobile application, the brake absorbs the kinetic energy of the

moving vehicle.

➢ In hoists and elevators, the brake absorbs the potential energy released by
the objects during the braking period.

➢ The energy absorbed by the brake is converted into heat energy and
dissipated to the surroundings. Heat dissipation is a serious problem in
brake applications.
Brakes are classified into the following three groups:
➢ Mechanical brakes, which are operated by mechanical means such as
levers, springs and pedals. Depending upon the shape of the friction
material, the mechanical brakes are classified as block brakes, internal or
external shoes brakes, disk brakes and band brakes.

➢ Hydraulic and pneumatic brakes, which are operated by fluid pressure such
as oil pressure or air pressure.

➢ Electrical brakes, which are operated by magnetic forces and which include
magnetic particle brakes, hysteresis brakes and eddy current brakes.
 Energy Equations
➢ The first step in the design of a mechanical brake is to determine the braking-torque
capacity for the given application.
➢ The braking-torque depends upon the amount of energy absorbed by the brake.
➢ When a mechanical system of mass m moving with a velocity v1 is slowed down to the
velocity v2 during the period of braking, the kinetic energy absorbed by the brake is
given by;
1
𝐾. 𝐸 = 𝑚 𝑣1 2 − 𝑣2 2
2
➢ Similarly, the kinetic energy of the rotating body is given by;
1 1
𝐾. 𝐸 = 𝐼 𝜔1 − 𝜔2 = 𝑚𝑘 2 𝜔1 2 − 𝜔2 2
2 2
2 2
Where, 𝐼 mass moment of inertia of the rotating body (kg-m2), 𝑘 = radius of gyration of the
body (m) and 𝜔1 , 𝜔2 = initial and final angular velocities of the body (rad/s)
 Energy Equations
➢ In certain applications like hoists, the brake absorbs the potential energy
released by the moving weight during the braking period.

➢ When a body of mass m falls through a distance h, the potential energy

absorbed by the brake during the braking period is given by;
𝑃. 𝐸 = 𝑚𝑔ℎ

➢ Therefore, the total energy absorbed by the brake is given by;

𝐸 = 𝐾. 𝐸 + 𝑃. 𝐸 = 𝑇 ∗ 𝜃
Example 3.1: A mass of 2500 kg is lowered at a velocity of 1.5 m/s from the
drum as shown in Fig. 12.1. The mass of the drum is 50 kg and its radius of
gyration can be taken as 0.7 m. On applying the brake, the mass is brought to
rest in a distance of 0.5 m. Calculate

i. the energy absorbed by the brake; and

ii. the torque capacity of the brake

BLOCK BRAKE WITH SHORT SHOE
➢ A block brake consists of a simple block, which is pressed against the rotating drum by
means of a lever as shown in Figure below.
➢ The friction between the block and the brake drum causes the retardation of the drum.
This type of brake is commonly employed in railway trains. The block is either rigidly
attached to the lever or, in some applications, pivoted to the lever.
➢ The angle of contact between the block and the brake drum is usually small. When it is
less than 45°, the intensity of pressure between the block and brake drum is uniform.
➢ The analysis is based on the following assumptions.
i. The block is rigidly attached to the lever.
ii. The angle of contact between the block and
brake drum is small, resulting in uniform
pressure distribution.
iii. The brake drum is rotating in clockwise direction.
➢ The free-body diagram of forces acting on the drum and the lever is shown in the figure;
➢ Considering the forces acting on the brake drum,
𝑇 = 𝜇𝑁𝑅
➢ The dimensions of the block are determined by
the following expression,
N = 𝑝𝑙𝑤
where, p = permissible pressure between the block and
the brake drum (N/mm2)
l = length of the block (mm)
w = width of the block (mm)
➢ The width of the block w is usually between one-fourth and one-half of the drum
diameter.
1 1 1
2𝑅 < 𝑤 < 2𝑅 → 𝑅 < 𝑤 < 𝑅
4 2 2
➢ Considering the equilibrium of forces in vertical and horizontal directions,
𝑅𝑥 = 𝜇𝑁
𝑅𝑦 = 𝑁 − 𝑝
➢ Taking the moment of force acting on the lever about the hinge point O,
𝑝𝑏 + 𝜇𝑁 ∗ 𝑐 − 𝑁 ∗ 𝑎 = 0
𝑁 ∗ 𝑎 − 𝜇𝑁 ∗ 𝑐
𝑝=
𝑏
𝑁(𝑎 − 𝜇 ∗ 𝑐)
𝑝=
𝑏
➢ Depending upon the magnitude of coefficient of friction (𝜇) and location of hinge pin (c),
there are three different cases.
i. 𝑎 >𝜇∗𝑐
ii. 𝑎 > 𝜇 ∗ 𝑐
iii. 𝑎 > 𝜇 ∗ 𝑐
i. 𝑎 > 𝜇 ∗ 𝑐 In this case, the friction force (𝜇 N) helps to reduce the magnitude of the
actuating force P. Such a brake is called a partially ‘self-energizing’ brake. However, the
brake is not self-locking, because a small magnitude of the positive force P is required
for the braking action. This is a very desirable condition.

ii. 𝑎 = 𝜇 ∗ 𝑐 In this case, the actuating force P is zero. This indicates that no external force
is required for the braking action. Such brake is called a ‘self-locking’ brake. This is not
a desirable condition in normal applications. Some positive braking effort (P) should be
required to apply the brake, otherwise the brake will be out of control of the operator.

iii. 𝑎 < 𝜇 ∗ 𝑐 Under this condition, the actuating force P becomes negative. This is a
dangerous operating condition, resulting in uncontrolled braking and grabbing. The
brake is out of control of the operator because he cannot apply it.
➢ Example 3.2: A single block brake with a torque capacity of 250 N-m is shown in
the figure below. The brake drum rotates at 100 rpm and the coefficient of friction is
0.35. Calculate;
i. the actuating force and the hinge-pin reaction for clockwise rotation of the drum;
ii. the actuating force and hinge-pin reaction for anticlockwise rotation of the drum;
iii. the rate of heat generated during the braking action; and
iv. the dimensions of the block, if the intensity of pressure between the block and brake
drum is 1 N/mm2. The length of the block is twice its width. State whether the brake is
self-locking.
➢ Double shoe brake
➢ Simple BAND BRAKE
➢ It consists of flexible leather or steel band which holds some parts of the circumference
of the drum.
➢ In simple band brake, one end of the band is attached to the end of the lever and
another end at the distance b from the end of the lever.
 𝑇1 Tension in the tight side of the band,
➢ Let
𝑇2 Tension in the slack side of the band,
𝜃 Angle of wrap(embrace) of the band on the drum in radian,
𝜇 Coefficient of friction between the drum and the band,
𝑟 Radius of the drum,
𝑤, 𝑡 Width and Thickness of the band respectively,
𝑡 Effective radius of the drum.
𝑟𝑒 = 𝑟 +
2

➢ The ratio of band tensions is given by,

𝑇1
= 𝑒 𝜇𝜃
𝑇2
➢ Therefore, the braking torque on the drum is,
𝑇 = 𝑇1 − 𝑇2 𝑟

➢ If the permissible tensile stress (𝜎𝑡 ) for the material of the band is known, then
maximum tension in the band is given by 𝑇1 = 𝜎𝑡 𝑤𝑡

➢ Now taking moments about the fulcrum O, we have;

➢ 𝑝𝑙 − 𝑇1 𝑏 = 0 →→−→ 𝑝𝑙 = 𝑇1 𝑏, for clockwise rotation of the drum,

➢ 𝑝𝑙 − 𝑇2 𝑏 = 0 →→−→ 𝑝𝑙 = 𝑇2 𝑏, for counter-clockwise rotation of the drum.

➢ Where, l = Length of the lever from the fulcrum (OC), and b = Perpendicular distance
from O to the line of action of T1 or T2.
➢ Example 3.3: In a simple band brake, the band is wrapped on the 3/4th of
circumference of the brake drum. The diameter of the brake drum is 500 mm. The
band brake provides a braking torque of 355 Nm. One end of the band is attached to a
fulcrum pin of the lever and the other end to a pin 150 mm from the fulcrum. A force is
applied on the lever at a distance of 600 mm from the fulcrum, the coefficient of
friction is 0.35, find the force applied on the end of the lever when the drum rotates in
the,

i. Clockwise rotation

ii. Counter-clockwise rotation

➢ Differential Band Brake
➢ A differential band brake as shown below, neither end of the band passes through the
fulcrum of the actuating lever. Such brakes can be designed for the condition of self-
locking.
➢ Considering forces acting on the lever and taking moments about the pivot O,

➢ 𝑝𝑙 + 𝑇1 𝑏 − 𝑇2 a = 0
➢ 𝑝𝑙 = 𝑇2 a − 𝑇1 𝑏
➢ We have seen that for self-locking brake, p ≤ 0. This implies that for self-locking
differential brake,
𝑻𝟐 𝒃
➢ 𝑝𝑙 ≤ 0 −→ 𝑇2 a − 𝑇1 𝑏 ≤ 0 −→ ≤
𝑻𝟏 𝒂
➢ Example 3.3: A differential band brake has an angle of contact of 215°. The band
has wrapped on a brake drum of 300 mm diameter. The brake is designed to provide a
torque of 450 N-m, the coefficient of friction between the band and the drum is 0.35.
The one end of the band is attached with the lever at point C and other end of the
band is attached at point D as shown in figure 8A and 8B. The lengths of OC and OD are
145 mm and 30 mm respectively. Perpendicular distance between the fulcrum and the
line of action of the force F is 600 mm. Find

i. The necessary force (F) for the anticlockwise and clockwise rotation of the drum;

ii. The value of ‘OC’ for self locking of the brake, when the drum rotates clockwise.
➢ Example 3.3:
➢