Brakes & Clutches

8
Brakes &
Clutches

BRAKES is a friction device used to regulate or stop the motion of a body

(Tordillo, 1998).

is a device used to bring a moving system to rest, to slow its speed,

or to control its speed to a certain value under varying conditions
(Mott, 1999).

are friction devices used to regulate the motion of bodies (slowing

them down, holding the speed constant, holding them at rest)
(Faires, 1969).

Types of brakes

Mechanical or friction brakes

o Band - the braking action is obtained by pulling the band tight onto the rotating wheel or
drum (band brake, differential band brake).
o Block - This brake works with friction force applied to the external surface of a rotating
cylinder using a block with a surface made of a suitable friction material. The braking
effect operates if the rotation is in either direction.
o Shoe - External-shoe brake operates in the same manner as the block brake. This type of
brake are used on elevator installations for locking the hoisting sheave by means of a

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heavy spring when the electric current is off and the elevator is at rest. Internal shoe
brake has several advantages over external shoe because it works on the inner surface of
the drum; it is protected from water and grit. This type of brake is usually used in the
automotive drum brake, with hydraulic piston actuation.
o Disc - This brake have long been used on hoisting and similar apparatus because more
energy is absorbed in prolonged braking than in clutch startup. Disk brakes are used for
the wheels of aircraft, where segmented rotary elements are pressed against stationary
plates by hydraulic pistons. Another application is the bicycle coaster brake.
o Spot brake
o Drum

Hydrodynamic brakes

o it utilizes fluid friction

Electrical brakes

o Utilizes the strength of electromagnetic fields; a brake that is given by an electric motor
can sometimes use its motor as a brake.

Hydraulic brakes

o Its principle works when the pedal of an automobile is depressed; a force is applied to a
piston in a master cylinder. The piston forces hydraulic fluid through metal tubing into a
cylinder in each wheel where the fluid’s pressure moves two pistons that press the brake
shoes against the drum.

Air brakes

o The fundamental principle involved is the use of compressed air acting through a piston
in a cylinder to set block brakes on the wheels. It is now widely used on railroad trains.
Used also on subway trains, trolley cars, buses, and trucks.

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Application of brakes

Used for motor vehicles, trains, airplanes, elevators, bicycles and other industrial machines.

Figure 8-1. Band brake

Where:

F = Applied Force (N)

P = Brake Power kW
M = Torque (Nm)
Fi = Actuating Force (N)
μ = Coefficient of Friction.
θt = Total band lap angle (rad)
w = Band width
a = Pivot- Actuating force radius (m)
b = Distance from tensioning belt to fulcrum point
n = Rotational Speed (RPM)
T1 = Maximum band tension (N)
T2 = Minimum band tension (N)
Tc = Band tension associated with centrifugal force (N)
p = pressure between band and drum surface (N/m2)
pmax = maximum pressure for friction surface (N/m2)

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Formula:
Tension in band brake

F1 /F2 = e f

Braking force

F1 – F2 = F
Where:
F1 – tension of the tight side of the band, lb
F2 – smaller tension, lb
f – coefficient of friction
θ – angle of contact between band and the wheel, radians

Power developed

P = 2πTn
Where: T – brake torque; n – speed of the drum

Brake torque

T = F (r)
T = F (D/2)
T = (F1 – F2) r
Where: r – radius of friction surface on the drum

Actuating force required, FA

M = FL
FA (a) = b (F2)
FA = b(F2)/a

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Pressure on brakes
Pmax = F1 / A
= F1 / br
Stress on brakes

S = F1 / bt
Where: b – width of the band; t – thickness of the band

Figure 8-2. Differential Band brakes

Braking torque, Tf

Tf = F (D/2)

Tf = W(D)a [(e)f – 1] / 2 [c – b (e) ]

Figure 8-3. Block brake

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Where:
F = Applied Force (N)
P = Brake Power kW
T = Torque (Nm)
F = Applied Force (N)
μ = Coefficient of Friction.
w = Band width
c = distance from tensioning belt to fulcrum point
n = Rotational Speed (RPM)
p = Maximum pressure for friction surface
max
θ = Brake shoe contact angle
r = Radius of brake wheel
Braking torque
T = Fr (μ) r
Maximum normal force applied by the block
F = Pmax.(r).θ.w
Maximum operating force
F = Fn(a - μc) / b

CLUTCH The function of a clutch is to transmit torque without slippage,

which occurs when the clutch doesn't completely carry the load it's
trying to move. Slippage shortens the life of clutches. Thus, any
clutch being considered must be able to transmit the required
torque.

EQUATIONS:

T = (5,252hK)/n

Where:
T = torque, lb-ft; h = horsepower; K = service, or safety, factor;
and n = speed, rpm.

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The value of K usually falls between 1.5 and 3, depending on how light or heavy the
application is. Light applications typically do not require full-rated torque during acceleration
and, therefore, can accept lower K values than heavy applications.

Equation for calculating the inertia of a solid shaft

wk2 = 0.000681 LD4

Where: wk2 = inertia, lb-ft2 ; = shaft material density, lb/ft3 ; L = shaft

length, ft; and D = shaft diameter, ft.

The inertia of a hollow shaft can be calculated by treating the shaft as solid and
subtracting the inertia of the hollow portion.

The reflected inertia of the load

wk2 R = wk2 L/r2

where: wk2 R = reflected inertia, lb-ft2 ; wk2 L = load inertia, lb-ft2 ;

and r = speed ratio.

If system inertia is known, the required torque is obtained from:

T = [(wk2 s)Δ s] /308.t

Where: T = torque, lb-ft; wk 2 s= system inertia, lbft 2 ; Δs = change in

speed or rpm; and t = time to speed (for clutch) or time to stop (for
brake).

Heat considerations are especially important in start-stop, or cycling, applications

because slippage occurs every time the clutch engages.

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The amount of heat generated during acceleration and deceleration can be calculated
from:
E = 1.7wk2 s C(N/100)2

Where: E = heat energy, lb-ft/min; lb-ft 2 ; C = number of starts or stops

per minute, or cycling rate; and N = rotational speed, rpm.

The heat-energy equation can also be rearranged to determine the maximum number of
cycles that can be produced by a clutch:

Cmax = (40A/wk2 s)(100/N2 )

Substituting Cmax into the heat-energy equation simplifies the equation to:
E = 1.7(40A)

Where: A = heat-dissipation factor, a value available from clutch

manufacturers.

PROBLEM
The motor is running the shaft at 500 rpm using a clutch. The clutch and brake are mounted on
the same shaft and cycle at a relatively high rate of 100 milliseconds (0.1 sec). System inertia
seen by either the clutch or brake is the same.

SOLUTION: To calculate the required clutch and brake torque, first compute the total system
inertia as seen by the clutch and brake. The accompanying table summarizes the parameters of
the inertia components in the system.

wk2= (0.000681)p.L.D4
= (0.000681)(0.269)(14)(0.5)4
= 0.00016 lb-ft 2
Calculations for the remaining components produce the following values:

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2
Secondary shaft inertia = 0.000083 lb-ft
2
Gear inertias = 0.0077 lb-ft
2
Roller inertias = 0.013 lb-ft
2
Thus, total system inertia is 0.042 lb-ft .

T = (wk2 s Δs/308t
= [(0.042)(500)] / [(308)(0.1)]
= 6.81 lb-ft

PROBLEM
Compute the axial force required for a cone clutch if it is to exert a driving torque of 15 ft-lb.
The cone surface has a mean diameter of 0.60 inch and angle of 120. Use f = 0.25.

SOLUTION

PROBLEM
Compute the actuation force required for the short shoe drum brake to produce a friction torque
of 150 ft-lb. Use a drum diameter of 12.0 in, a = 4.0 and L = 24.0. Use f = 0.25 and b = 5 in.

SOLUTION

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PROBLEM
Compute the axial force required for cone angles 100, 120, 150 for a cone brake if it is to exert a
braking torque of 50 ft-lb. The mean radius of the cone is 5.0 in. Use f = 0.25.

SOLUTION
T = 50 ft-lb
f = 0.25
rm = 5
cone angles = 100, 120, 150

Formula

T=

Fa =

Fa = 480(sinα + 0.25 cosα)

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Design Exercises

PROBLEM
Compute the dimensions of an annular plate-type brake to produce a braking torque of 300 in-lb.
spring will provide a normal force of 320 lb between the friction surfaces. Coefficient of friction
is 0.25. The brake will be used in average industrial service, stopping a load from 750 rpm. (R o =
1.5Ri)

SOLUTION

PROBLEM
Compute the torque that a clutch must transmit to accelerate the pulley from rest to 550 rpm in
2.5 sec of the steel-belt pulley, Wk2 = 79.64 ft2-lb. Ans. T =

SOLUTION

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PROBLEM
A simple band brake has a 76 cm drum fitted with a steel band 0.40 cm thick lined with asbestos
lining having a coefficient of friction, 0.25. The arc of contact is 245 0. The drum is attached to a
60 cm hoisting drum, which sustains a rope load of 820 kg. The operating force has a moment
arm of 1.5 m and band is attached 12 cm from the pivot point.
Find:
a. torque required to support the load
b. force P required if the direction of rotation is reversed
c. width of steel band for a tensile stress of 50 N/mm2.

SOLUTION
D = 76 cm
t = 0.40 cm
f = 0.25
θ = 245
lever arm = 1.5 m
rope load = 820 kg
d = 60 cm

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PROBLEM
Compute the actuation force required for the short shoe drum brake to produce a friction torque
of 50 ft-lb. Use a drum diameter of 10 inches, a = 3 in, and L = 15 inches. Values for f are 0.25,
0.50 and 0.75, and different points of location of pivot A such that B ranges from 0 to 6 inches.
Ans. W = 8(3/f-b) lbs

SOLUTION

PROBLEM
Specify the required torque rating for a clutch to be attached to an electric motor shaft running at
1150 rpm. The motor is rated at 0.50 hp drives a light fan.

SOLUTION

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Assignment # __
Find machinery or device/machines that have brakes or clutch application. Have a picture of it
and identify the details of the machine element and compute the power needed to operate such
machine. Submit this requirement(s) on ___________.

Notes

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DESIGN PROBLEM # 8

Name: Rating:
Course/Yr: Date:

SHOE BRAKE DESIGN

PROBLEM
A shoe brake with a torque capacity of 2000 in-lb at 600 rpm and f = 0.25. Determine the
following:
a. total normal force between shoe and brake wheel
b. total friction force
c. force required to brake against counter clockwise direction
d. force required to brake against clockwise direction
e. heat generation

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DESIGN PROBLEM # 8 continuation

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