MACHINE DESIGN II

Dr Sangarappillai Sivaloganathan
30th August 2020

Friction Elements
LECTURE 1.1
 AGENDA
▪ Introduction to Friction Elements
▪ Free Body Diagram
▪ Friction
▪ Brakes and Types
▪ Shoe Brakes
▪ Energy consideration for Shoe Brakes
▪ Examples on Block Brakes
 FRICTION ELEMENTS
▪ Devices designed specifically to produce friction are called
Friction Elements.
 FRICTION ELEMENTS

▪ Devices designed specifically to produce friction are called

Friction Elements.
 FREE BODY DIAGRAM

▪ A Free Body Diagram is a force diagram, that represents all the

forces acting upon an object.
▪ Types of Forces
▪ Body forces – Such as the weight, Centrifugal forces,
Magnetic forces etc.
▪ Contact forces – Reactions normal to the surface
▪ Surface forces – Pressure, viscous forces
▪ Point forces

▪ Devices designed specifically to produce friction are called

Friction Elements.
 FREE BODY DIAGRAM

▪ Gravity Force
▪ Force from string, rope, wire, cable etc
▪ Force from springs
▪ Frictional force when two surfaces try to slide on each other
▪ Reactions when two surfaces press on each other
▪ Applied forces when a person pushes or pulls
 FREE BODY DIAGRAM - EXAMPLE

▪ A Free Body Diagram is a force diagram, that represents all the

forces acting upon an object.
 FREE BODY DIAGRAM

▪ A Free Body Diagram is a force diagram, that represents all the

forces acting upon an object.
▪ Types of Forces
▪ Body forces – Such as the weight, Centrifugal forces,
Magnetic forces etc.
 FREE BODY DIAGRAM

▪ A Free Body Diagram is a force diagram, that represents all the

forces acting upon an object.
▪ Types of Forces
▪ Body forces – Such as the weight, Centrifugal forces,
Magnetic forces etc.
▪ Contact forces – Reactions normal to the surface
 FREE BODY DIAGRAM

▪ A Free Body Diagram is a force diagram, that represents all the

forces acting upon an object.
▪ Types of Forces
▪ Body forces – Such as the weight, Centrifugal forces,
Magnetic forces etc.
▪ Contact forces – Reactions normal to the surface
▪ Surface forces – Pressure, viscous forces
 FREE BODY DIAGRAM

▪ A Free Body Diagram is a force diagram, that represents all the

forces acting upon an object.
▪ Types of Forces
▪ Body forces – Such as the weight, Centrifugal forces,
Magnetic forces etc.
▪ Contact forces – Reactions normal to the surface
▪ Surface forces – Pressure, viscous forces
▪ Point forces
 FRICTION

▪ Friction is an opposing force between two surfaces that are

sliding or trying to slide across each other.
▪ Kinetic Friction is defined as a force that acts between moving
surfaces to oppose the motion.
▪ The magnitude of the kinetic friction force is dependent on the
coefficient of friction and the normal force forcing the surfaces
together.
▪ Static friction is the frictional force that acts between surfaces
that try to move but not moving.
▪ It will increase as the magnitude of the effort to move until the
motion begins.
 CLUTCHES AND BRAKES
▪ Two inertias, I1 and I2, traveling at the respective angular
velocities ω1 and ω2, one of which may be zero in the case of
brakes, are to be brought to the same speed by engaging the
clutch or brake.
▪ Brakes are devices that dissipate kinetic energy of the moving
parts of a machine. In mechanical brakes the dissipation is
achieved through sliding friction between a stationary object
and a rotating part.
 BRAKES

▪ Brakes are devices that dissipate kinetic energy of the moving

parts of a machine.
▪ In mechanical brakes the dissipation is achieved through sliding
friction between a stationary object and a rotating part.
▪ Depending upon the direction of application of braking force,
the mechanical brakes are primarily of three types
▪ Shoe or block brakes – braking force applied radially
▪ Band brakes – braking force applied tangentially.
▪ Disc brake – braking force applied axially.
 TYPES OF BRAKES
▪ Shoe or block brakes – braking force applied radially
▪ Band brakes – braking force applied tangentially.
▪ Disc brake – braking force applied axially.
 SHOE BRAKES

▪ The force needed to secure contact is supplied by a lever.

▪ When a force F is applied to the shoe frictional force
proportional to the applied force develops.
 SINGLE SHOE BRAKES

▪ The force needed to secure contact is supplied by a lever.

▪ When a force F is applied to the shoe frictional force
proportional to the applied force develops.
▪ depends on friction material and the geometry of the shoe.
▪ Though the exact nature of the contact pressure distribution is
unknown, an approximation (based on wear considerations) is
made as

▪ Where the angle is measured from the center-line of the shoe

 EXAMPLE - BLOCK BRAKE

▪ Train Wagon Wheel Brake is a good example of Block Brake

Application
 SINGLE SHOE BRAKES

▪ If 𝜇𝑎 > 𝑥.then P is not needed to engage the brake. This is

called self locking brake.
▪ If 𝜇𝑎 < 𝑥.then P is needed to engage the brake.
▪ The phenomenon of Frictional force aiding the brake actuation
is called self-energization.
 SELF ENERGIZATION

▪ The phenomenon of Frictional force aiding the brake actuation

is called self-energization.
▪ Here the Friction Force is not working with the effort.
 SELF ENERGIZING IN DRUM BRAKES
▪ The troubles with self-energizing brakes are equally well known.
They are very susceptible to changes in the coefficient of
friction, which naturally changes the multiplication factor.
▪ If the brake gets hot on a descent, which lowers the coefficient
of friction, the multiplication factor gets smaller and the brakes
can barely stop the car, a condition known as heat fade.
▪ Conversely, if anything raises the coefficient of friction, such as
escaped lubricant (which makes brake material sticky), the
coefficient of friction rises and the brakes lock with the slightest
application.
ENERGY DISSIPATED DURING BRAKING
 ENERGY DISSIPATED DURING BRAKING
▪ The phenomenon of Frictional force aiding the brake actuation is
called self-energization.
▪ Here the Friction Force is not working with the effort.
ENERGY DISSIPATION AT THE BRAKE DRUM
 EXAMPLE 1
▪ A single block brake shown in figure has a drum diameter of 300
mm and the angle of contact is 50 degrees. The drum operates in
the clockwise direction. If the operating force of 1000 N is applied
at the end of the lever and the coefficient of friction is 0.35
determine the torque that may be transmitted by the block brake.

Torque = Frictional force x Drum radius

Drum rotating in clockwise has to be slowed down.
Therefore frictional force on drum and torque should be counterclockwise.
The force on brake shoe will be in the opposite direction.
 EXAMPLE 1 – FREE BODY DIAGRAM
▪ Free body diagram shows all forces on the lever –shoe assembly.
▪ At the pivot point there will be force components in x and y
direction
▪ There will be a Normal reaction RN from drum to the shoe.
▪ The frictional force Ft will be in the direction of rotation
 EXAMPLE 1 – Solution

Taking moment about the fulcrum gives

1000 × 450 + 𝐹𝑡 × 50 = 𝑅𝑁 × 200
𝐹 𝐹𝑡
But 𝑅𝑁 = 𝜇𝑡 = 0.35
571.4 𝐹𝑡 − 50𝐹𝑡 = 450,000
450,000
𝐹𝑡 = = 863 𝑁
521.4
Therefore Torque = 𝐹𝑡 × 𝑟 = 863 × 0.15 = 129.46 𝑁𝑚
 EXAMPLE 2
▪ A single block brake shown in Figure has a drum diameter of 250
mm and the angle of contact is 60 degrees. The drum is rotating
in the clockwise direction. The coefficient of friction is 0.385. If
the torque transmitted is 70 Nm determine the Force P required
to operate the brake.

Torque = Frictional force x Drum radius

Drum rotating in clockwise has to be slowed down.
Therefore frictional force on drum and torque should be counterclockwise.
The force on brake shoe will be in the opposite direction.
 EXAMPLE 2 – FREE BODY DIAGRAM
▪ Free body diagram shows all forces on the lever –shoe assembly.
▪ At the pivot point there will be force components in x and y
direction
▪ There will be a Normal reaction RN from drum to the shoe.
▪ The frictional force Ft will be in the direction of rotation
 EXAMPLE 2 – FREE BODY DIAGRAM

Consider the forces on the lever.

Taking moment about the fulcrum gives
𝑃 × 400 + 𝐹𝑡 × 50 = 𝑅𝑁 × 200
𝐹 𝐹
But 𝑅𝑁 = 𝑡 = 𝑡
𝜇 0.385
519.5 𝐹𝑡 − 50𝐹𝑡 = 𝑃 × 400
But the torque = 𝐹𝑡 × 0.125 = 70
70
Hence 𝐹𝑡 = = 560
0.125
469.5 × 560
𝑃= = 657.3 𝑁
400
 EXAMPLE 3
• The block brake shown in figure provides a braking torque of 360
Nm. The diameter of the brake drum is 300 mm. The coefficient of
friction is 0.3. Find (a) the force P to be applied at the end of the
lever for clockwise and counter clockwise rotation of the brake
drum and (b) the location of the pivot fulcrum to make the brake
self-locking for the clockwise rotation of the brake drum.

Torque = Frictional force x Drum radius

 EXAMPLE 3 – CLOCKWISE ROTATION

▪ Free body diagram shows all forces on the lever –shoe

assembly.
▪ At the pivot point there will be force components in x and y
direction
▪ There will be a Normal reaction RN from drum to the shoe.
▪ The frictional force Ft will be in the direction of rotation
 EXAMPLE 3 – CLOCKWISE ROTATION
800 PN
PN RN
200

Ft
50

Drum Drum

Clockwise rotation
Torque = 𝐹𝑡 × 0.15 = 360
360
Hence 𝐹𝑡 = 0.15 = 2400𝑁
Taking moment about the fulcrum gives
𝐹𝑡
𝑃 × 800 = × 200 − 𝐹𝑡 × 50 = 616.67 𝐹𝑡
0.3
616.67×2,400
Hence 𝑃 = = 1850 𝑁
800
 EXAMPLE 3 – COUNTER CLOCKWISE ROTATION
▪ Free body diagram shows all forces on the lever –shoe assembly.
▪ At the pivot point there will be force components in x and y
direction
▪ There will be a Normal reaction RN from drum to the shoe.
▪ The frictional force Ft will be in the direction of rotation
EXAMPLE 3 – COUNTER CLOCKWISE ROTATION

Counter Clockwise rotation

Torque = 𝐹𝑡 × 0.15 = 360
360
Hence 𝐹𝑡 = = 2400𝑁
0.15
Taking moment about the fulcrum gives
𝐹𝑡
𝑃 × 800 = × 200 + 𝐹𝑡 × 50 = 716.67 𝐹𝑡
0.3
716.67×2,400
Hence 𝑃 = = 2,150 𝑁
800
 EXAMPLE 3 – SELF LOCKING

Self-locking takes place when friction aids the effort or self-energizing

Let the Fulcrum be at a distance ‘a’ instead of the 50 mm in the figure.
Taking moment about the fulcrum gives
𝐹𝑡
𝑃 × 800 = × 200 − 𝐹𝑡 × 𝑎
0.3
For self-locking this should be zero.
𝐹
This gives 0.3𝑡 × 200 − 𝐹𝑡 × 𝑎 = 0
Hence 𝑎 = 666.7 𝑚𝑚
 EXAMPLE 4 – DOUBLE SHOE BRAKE
• The layout and dimensions of a double shoe brake is shown in
figure. The diameter of the brake drum is 300 mm and the contact
angle is 90 degrees. If the coefficient of friction for the brake lining
and the drum is 0.4 find the spring force necessary to transmit a
torque of 30 Nm. Also determine the width of the brake shoes if the
braking pressure should not exceed 0.28 MPa.

4𝜇 sin 𝜃
𝜇′ =
2𝜃 + sin 2𝜃

Torque = Frictional force x Drum radius

 EXAMPLE 3 – CLOCKWISE ROTATION
4×0.4×sin 45
Effective coefficient of friction = (𝜋Τ2+1) = 0.44
Torque by both arms = 30 Nm
Torque= (𝐹𝑡1 +𝐹𝑡2 ) × 0.15 = 30
Hence (𝐹𝑡1 +𝐹𝑡2 ) = 200
Taking moment about the fulcrum for arm 1 gives
𝐹𝑡
𝑆 × 475 + 𝐹𝑡 × 150 = × 225
0.44
225
𝑆 = 𝐹𝑡1 × − 150 ÷ 475
0.44
Hence 𝐹𝑡1 = 1.3145 𝑆
Similarly
Taking moment about the fulcrum for arm 2 gives
𝐹𝑡
𝑆 × 475 − 𝐹𝑡2 × 150 = × 225
0.44
225
𝑆 = 𝐹𝑡2 × + 150 ÷ 475
0.44
Hence 𝐹𝑡2 = 0.7182 𝑆
Adding both gives (𝐹𝑡1 +𝐹𝑡2 ) = 1.3145𝑆 + 0.7182 𝑆 = 2.0327𝑆
200
Hence 𝑆 = 2.0327 = 98.4 𝑁
1.3145 × 98.4
𝑅𝑁1 =
0.44
 EXAMPLE 4 – CLOCKWISE ROTATION
Similarly
Taking moment about the fulcrum for arm 2 gives
𝐹𝑡
𝑆 × 475 − 𝐹𝑡2 × 150 = × 225
0.44
225
𝑆 = 𝐹𝑡2 × + 150 ÷ 475
0.44
Hence 𝐹𝑡2 = 0.7182 𝑆
Adding both gives (𝐹𝑡1 +𝐹𝑡2 ) = 1.3145𝑆 + 0.7182 𝑆 =
2.0327𝑆
200
Hence 𝑆 = 2.0327 = 98.4 𝑁
1.3145 × 98.4
𝑅𝑁1 =
0.44
1.3145×98.4
Hence at limiting point 0.28 = 0.44×𝑏×𝜋Τ2×150
Thus 𝑏 = 4.46 𝑚𝑚
Rounding up this becomes 5 mm
 SUMMARY

▪ Introduction to Friction Elements

▪ Free Body Diagram
▪ Friction
▪ Brakes and Types
▪ Shoe Brakes
▪ Energy consideration for Shoe Brakes
▪ Examples on Block Brakes