ME 211: Machine Design

Module 3

Design of Clutches: Types of clutches, Disc Clutches, Clutch material, and

selection
Design of brakes : Types of Brakes, Shoe, Band and Disk Brakes, Brake selection
and specification, Brake materials
Mechanical Brakes
Brakes are used to dissipate kinetic energy of a body/part/machine element and
reduce its speed or completely stop it.

Block Brake Drum Brake Disc Brake

Band Brake
 Courtesy: MechStuff

Mechanical Brakes

Block/Shoe Brake Band Brake

Band & Block Brake Disc Brake

Internally Expanding Brakes Hydraulic Brakes

Courtesy: MechStuff
Block or Shoe Brake (short)

✓ A block brake consists of a simple block, which is pressed against the rotating drum
by means of a lever.
✓ 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.

1 1
drum diameter < Block width < (drum diameter)
4 2
• Normal Force applied on the drum (𝑵) is
along the same direction in which the
force P was applied. We can see both N
and P acting upwards.
• Reaction of the upward force 𝑵 is felt by
the block. The reaction force is same in
magnitude as force 𝑵, just in downward
direction. 𝝁𝑵
• 𝜇𝑁 is the friction force. First see 𝑵
direction of velocity of drum at the point
of contact (CW, going left), then take 𝝁𝑵 𝑵
in opposite direction on drum (towards 𝝁𝑵
right).

• Since all the contact forces between

block and drum will be in opposite
direction (Newton third law), so 𝝁𝑵 on
lever will be in opposite direction of
𝝁𝑵 on rotating drum. Forces occur in pair and they act on
different bodies
Magnitude of braking torque = Friction force x radius of drum Red font: Action
= 𝜇𝑁 × 𝑅 Green font: Reaction
Magnitude of braking torque = Friction force x radius of drum 𝑵
= 𝜇𝑁 × 𝑅 𝝁𝑵

Take moment about hinge O and apply σ 𝑀 = 0

𝑃 × 𝑏 + 𝜇𝑁 × 𝑐 = 𝑁 × 𝑎

Solve to get N and put in the formula of braking torque. Simple!!!

Braking torque, TB = 𝜇𝑁 × 𝑅

𝑃𝑏 + 𝜇𝑁𝑐 = 𝑁𝑎 Don’t MUG-Up this formula, obtain this equation

using σ 𝑀 = 0, as it will be changing with different
cases (or even with rotation of drum).
𝑁 𝑎 − 𝜇𝑐
⇒𝑃=
𝑏
 𝑁 𝑎 − 𝜇𝑐
𝑃=
𝑏
Case-I: 𝑎 = 𝜇𝑐
∴𝑃=0 This indicates that no external force is required for the braking
action. Such a brake is on the verge of ‘self-locking’ brake. Not
desired.
Case-II: 𝑎 < 𝜇𝑐
This is a dangerous operating condition, resulting in
∴ 𝑃 = −𝑣𝑒 uncontrolled braking and grabbing. The brake is out of
control of the operator because he cannot apply it. Such a
brake is called ‘self-locking’ brake.
Case-III: 𝑎 > 𝜇𝑐
In this case, the friction force helps to reduce the magnitude
∴ 𝑃 = +𝑣𝑒
of the actuating force P. Such a brake is called a ‘self-
energizing’ brake.
Similarly, can obtain
Anticlockwise rotation of drum
Take moment about hinge O and apply σ 𝑀 = 0

𝑃𝑏 − 𝜇𝑁𝑐 = 𝑁𝑎
𝑁 𝑎 + 𝜇𝑐
⇒𝑃=
𝑏
𝝁𝑵
Therefore, the braking effort (P) also
depends upon the direction of rotation of 𝑵
the brake drum. 𝑵
Obviously, for anti-clockwise rotation, the 𝝁𝑵
actuating force or braking effort (P) is more
than that of clockwise rotation

In design, the objective will be to have

smaller values of braking effort.
It is observed from the above analysis that the percentage of total brake effort that
results from self-energizing action depends upon the following three factors:

(i) The location of pivot for the brake lever or brake arm, namely, dimensions a and c

(ii) The coefficient of friction

(iii) The direction of rotation of brake drum

The main disadvantage of the block brake is the tendency of the brake drum shaft to
bend under the action of normal reaction. The remedy is to use two symmetrical
blocks at the opposite sides of the brake drum.
Block or Shoe Brake (long)

When angle of contact, 2𝜃 > 45°

4𝑠𝑖𝑛𝜃
𝜇′ =𝜇
2𝜃 + 𝑠𝑖𝑛2𝜃

Braking torque, TB = 𝜇′𝑁 × 𝑅

𝜇′ : Equivalent coefficient of friction

𝜇: Actual coefficient of friction
Block Brake with Long Shoe

Rest all same

Revision :Block or Shoe Brake (short)
Clockwise rotation of drum Anticlockwise rotation of drum

𝝁𝑵 𝝁𝑵
𝑵 𝑵
𝑵 𝑵
𝝁𝑵 𝝁𝑵

𝑃𝑏 + 𝜇𝑁𝑐 = 𝑁𝑎 𝑃𝑏 − 𝜇𝑁𝑐 = 𝑁𝑎
Magnitude of braking torque = Friction force x radius of drum
= 𝜇𝑁 × 𝑅
Block or Shoe Brake (long)

When angle of contact, 2𝜃 > 45°

4𝑠𝑖𝑛𝜃
𝜇′ =𝜇
2𝜃 + 𝑠𝑖𝑛2𝜃

Braking torque, TB = 𝜇′𝑁 × 𝑅

𝜇′ : Equivalent coefficient of friction

𝜇: Actual coefficient of friction
Block Brake with Long Shoe

Rest all same

Numerical 1
The block brake, as shown in Figure, provides a braking torque of 360 N-m.
The diameter of the brake drum is 300 mm. The coefficient of friction is 0.3. Find :
1. The force (P) to be applied at the end of the lever for the clockwise and counter-clockwise
rotation of the brake drum; and
2. The location of the pivot or fulcrum to make the brake self locking for the clockwise rotation of
the brake drum.

𝜇𝑁
𝑁
The block brake, as shown in Figure, provides a braking torque of 360 N-m.
The diameter of the brake drum is 300 mm. The coefficient of friction is 0.3. Find :
1. The force (P) to be applied at the end of the lever for the clockwise and counter-clockwise
rotation of the brake drum; and
2. The location of the pivot or fulcrum to make the brake self locking for the clockwise rotation of
the brake drum.

𝜇𝑁
𝑁
Numerical 2
A single block brake is shown in Figure. The diameter of the drum is 250 mm and the
angle of contact is 90°. If the operating force of 700 N is applied at the end of a lever
and the coefficient of friction between the drum and the lining is 0.35, determine the
torque that may be transmitted by the block brake.
Solve Example 12.4 from V. B. Bhandari Book
BAND BRAKES

• It consists of a flexible steel strip lined with friction material, which is pressed
against the rotating brake drum.

• When one end of the steel band passes through the fulcrum of the actuating
lever, the brake is called the simple band brake.
Summary: Band Brake

Clockwise rotation of drum Anticlockwise rotation of drum

𝑃1
= 𝑒 𝜇𝜃
𝑃2

𝑷𝟐 𝑷𝟏
𝑷𝟏 𝑷𝟐

𝑎 𝑎

𝑃2 𝑎 = 𝑃𝑙 𝑃1 𝑎 = 𝑃𝑙

𝑃1 = tension on the tight side of the band (N)

𝑃2 = tension on the loose (slack) side of the band (N)
𝜇 = coefficient of friction between the friction lining and the brake drum
𝜃 = angle of wrap (radian)
𝑅 = Radius of drum
Braking Torque, 𝑇𝐵 = 𝑃1 − 𝑃2 𝑅
Numerical 3

A band brake having band-width of 80 mm, drum diameter of 250 mm, coefficient
of friction of 0.25 and angle of wrap of 270 degrees is required to exert a friction
torque of 1000 N-m. The maximum tension (in kN) developed in the band is

𝑷𝟐
𝑷𝟏
𝑎
DISK BRAKES

Similar to a plate clutch, except that

one of the shafts is replaced by a
fixed member.

𝑭 𝑭

The equations derived for single-plate clutch are also applicable to disk brake.

However, disk brakes are never made with friction lining covering the entire
circumference of the plate, because it would result in overheating. The braking pad
presses only a small fraction of the circumference.
Disk Brake with Annular Pad

𝑅𝑜 = outer radius of pad

𝑅𝑖 = inner radius of pad 𝑭 𝑭
𝜃 = angular dimension of pad (radians)

Since the area of the pad is comparatively

small, it is assumed that pressure on
friction lining is uniform.

The friction radius (𝑅𝑓 ) for uniform pressure theory is given by

1 𝐷3 −𝑑 3 2 𝑅𝑜3 −𝑅𝑖3
𝑅𝑓 = using 𝐷 = 2𝑅𝑜 and 𝑑 = 2𝑅𝑖 ⇒ 𝑅𝑓 =
3 𝐷2 −𝑑 2 3 𝑅𝑜2 −𝑅𝑖2

Braking torque, 𝑇𝐵 = 𝜇𝐹𝑅𝑓

𝜃 1
∵ Area of pad, 𝐴 = 𝜋 𝑅𝑜2 − 𝑅𝑖2 = 𝜃 𝑅𝑜2 − 𝑅𝑖2
2𝜋 2

Actuating force, 𝐹 = Average pressure × Area of pad

∴ 𝐹 = 𝑝𝑎𝑣𝑔 × 𝐴
Disk brake with a circular pad

𝑅 = radius of pad (mm)

𝑒 = distance of pad centre from 𝑭 𝑭
the axis of disk (mm)

The friction radius (𝑅𝑓 ) of circular pad is

given by
𝑅𝑓 = 𝛿𝑒

∴ 𝑇𝐵 = 𝜇𝐹𝑅𝑓
Numerical 4
Following data is given for a caliper disk brake with annular pad, for the front
wheel of the motorcycle:
torque capacity = 1500 N-m
outer radius of pad = 150 mm
inner radius of pad = 100 mm
coefficient of friction = 0.35
average pressure on pad = 2 MPa
number of pads = 2 𝑭 𝑭
Calculate the angular dimension of the pad.
Following data is given for a caliper disk brake with annular pad, for the front
wheel of the motorcycle:
torque capacity = 1500 N-m
outer radius of pad = 150 mm
inner radius of pad = 100 mm
coefficient of friction = 0.35
average pressure on pad = 2 MPa
number of pads = 2 𝑭 𝑭
Calculate the angular dimension of the pad.
Solve Example 12.13 from V. B. Bhandari Book
Quiz based on Module 2
on
Monday, 14 March
at 2:40 PM (20 minutes)

Quiz based on Module 3

on
Thursday, 24 March
at 4:40 PM (30 minutes)