Design of Brakes

Prof Sumit Suresh Malusare

Finolex Academy Of Management & Technology,
Ratnagiri

Prof Sumit Suresh Malusare,FAMT,Ratnagiri

Introduction
• Brake is defined as mechanical device which is used to absorb energy
possessed by moving system or mechanism by means of friction.
• Primary purpose of brake is to slow down or completely stop motion
of moving system.
• It is also used to hold the system in rest.

Prof Sumit Suresh Malusare,FAMT,Ratnagiri

 Classification of
Brakes

Prof Sumit Suresh Malusare,FAMT,Ratnagiri

Prof Sumit Suresh Malusare,FAMT,Ratnagiri
Prof Sumit Suresh Malusare,FAMT,Ratnagiri
Applications of different types of Brakes

Prof Sumit Suresh Malusare,FAMT,Ratnagiri

Design of Single shoe brake
Case 1-: Tangential force passing through fulcrum of lever

• Taking moment about point o

𝑃×𝑙
• 𝑅𝑁 × 𝑥 = 𝑃 × 𝑙 → 𝑅𝑁 =
𝑥
𝜇𝑃𝐿𝑟
• Breaking torque 𝑇𝐵 = 𝜇𝑅𝑁 𝑟 =
𝑥
• Above condition is true for both rotations
Prof Sumit Suresh Malusare,FAMT,Ratnagiri
Design of Single shoe brake
Case 2-: Tangential force passing through distance below fulcrum of lever by
distance a

• Taking moment about point o • Taking moment about point o

• 𝑅𝑁 × 𝑥 + 𝐹𝑡 × 𝑎 = 𝑃 × 𝑙 • 𝑅𝑁 × 𝑥 − 𝐹𝑡 × 𝑎 = 𝑃 × 𝑙
• 𝑅𝑁 × 𝑥 + 𝜇𝑅𝑁 × 𝑎 = 𝑃 × 𝑙 • 𝑅𝑁 × 𝑥 − 𝜇𝑅𝑁 × 𝑎 = 𝑃 × 𝑙
𝑃×𝑙 𝑃×𝑙
• 𝑅𝑁 = • 𝑅𝑁 =
𝑥+𝜇𝑎 𝑥−𝜇𝑎
𝜇𝑃𝐿𝑟 𝜇𝑃𝐿𝑟
• Breaking torque 𝑇𝐵 = 𝜇𝑅𝑁 𝑟 = • Breaking torque 𝑇𝐵 = 𝜇𝑅𝑁 𝑟 =
𝑥+𝜇𝑎 𝑥−𝜇𝑎

Prof Sumit Suresh Malusare,FAMT,Ratnagiri

Design of Single shoe brake
Case 3-: Tangential force passing through distance above fulcrum of lever by
distance a

• Taking moment about point o

• Taking moment about point o
• 𝑅𝑁 × 𝑥 − 𝐹𝑡 × 𝑎 = 𝑃 × 𝑙
• 𝑅𝑁 × 𝑥 + 𝐹𝑡 × 𝑎 = 𝑃 × 𝑙
• 𝑅𝑁 × 𝑥 − 𝜇𝑅𝑁 × 𝑎 = 𝑃 × 𝑙
• 𝑅𝑁 × 𝑥 + 𝜇𝑅𝑁 × 𝑎 = 𝑃 × 𝑙
𝑃×𝑙
• 𝑅𝑁 = 𝑃×𝑙
𝑥−𝜇𝑎 • 𝑅𝑁 =
𝜇𝑃𝐿𝑟 𝑥+𝜇𝑎
• Breaking torque 𝑇𝐵 = 𝜇𝑅𝑁 𝑟 = 𝜇𝑃𝐿𝑟
𝑥−𝜇𝑎 • Breaking torque 𝑇𝐵 = 𝜇𝑅𝑁 𝑟 =
𝑥+𝜇𝑎

Prof Sumit Suresh Malusare,FAMT,Ratnagiri

Design of Single shoe brake…
• Now consider anticlockwise condition from case 2 and clockwise
condition from case 3
• 𝑅𝑁 × 𝑥 = 𝑃 × 𝑙 + 𝜇𝑅𝑁 × 𝑎
• In above case frictional force helps to apply brake, such condition is
called as self energizing condition
• When frictional force as high such that it apply break without external
force such condition is called as self locking condition
• Condition for break to self locking is 𝑥 ≤ 𝜇𝑎. This condition is used in
backstop application.

Prof Sumit Suresh Malusare,FAMT,Ratnagiri

Pivoted Shoe brake
• If angle of contact is greater than 60° then
pivoted shoe is used.
• This gives uniform wear of break shoe in
the direction of applied force
• In such case equivalent coefficient of
friction is given by
4𝜇 sin 𝜃
• 𝜇𝑒𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 =
2𝜃+sin 2𝜃
• Such arrangement has higher life and
greater breaking torque

Prof Sumit Suresh Malusare,FAMT,Ratnagiri

Numericals on Brakes
• The block type hand brake shown in fig.
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;
• Effort F
• Maximum torque,
• 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.

Prof Sumit Suresh Malusare,FAMT,Ratnagiri

Determination of normal force acting on lever
• Since angle 2𝜃 > 60° hence equivalent
coefficient of friction
4 sin 𝜃
• 𝜇𝐼 = 𝜇
2𝜃+sin 2𝜃
• 𝜇 = 0.24 ----- Given
• 2𝜃 = 90° = 1.5707 𝑅𝑎𝑑
• 𝜇𝐼 = 0.264
• Allowable pressure
𝑅𝑁
•𝑃=
2𝑤𝑟 sin 𝜃
• 𝑃 = 0.6 𝑁Τ𝑚𝑚2 --- Given
• 𝑤 width of brake shoe= 45 mm given
• 𝑟 radius of drum = 150 mm ---- Given
• 𝑅𝑁 = 5727.5649 N
Prof Sumit Suresh Malusare,FAMT,Ratnagiri
 Determination of breaking Torque
• Tangential force
• 𝐹𝑡 = 𝜇𝐼 × 𝑅𝑁
• 𝜇𝐼 = 0.264
• 𝑅𝑁 = 5727.5649 N
• 𝐹𝑡 = 1512.0771 𝑁
• Taking Moment about Fulcrum point
• 𝑅𝑁 × 𝑏 = 𝐹 × 𝑎
• 𝑅𝑁 = 5727.5649 N
• 𝑎 = 500 𝑚𝑚
• 𝑏 = 200 𝑚𝑚
• Effort 𝐹 = 2291.0219 𝑁 PSG 7.97

Prof Sumit Suresh Malusare,FAMT,Ratnagiri

Determination of breaking Torque…
• Breaking Torque
• 𝑀𝑡 𝐵𝑟𝑒𝑎𝑘𝑖𝑛𝑔 = 𝐹𝑡 × 𝑟
• 𝐹𝑡 = 1512.0771 𝑁
• 𝑟 = 150 mm
• 𝑀𝑡 𝐵𝑟𝑒𝑎𝑘𝑖𝑛𝑔 = 226811.565 𝑁𝑚𝑚 = 226.8116 𝑁𝑚

Prof Sumit Suresh Malusare,FAMT,Ratnagiri

Determination of heat generated
• Power Absorbed
2𝜋𝑁𝑀𝑡𝐵
•𝑃=
60
• 𝑀𝑡 𝐵𝑟𝑒𝑎𝑘𝑖𝑛𝑔 = 226811.565 𝑁𝑚𝑚 = 226.8116 𝑁𝑚
• 𝑁 = 100 𝑅𝑝𝑚 ---- Given
Nm
•𝑃= 2375.1652 = 2375.1652 Watts
sec
• Heat Generated
• 𝐻𝑔 = 𝑃 × 𝑇𝑖𝑚𝑒 𝑜𝑓 𝑏𝑟𝑒𝑎𝑘𝑖𝑛𝑔
• Time of breaking = 5 sec --- Given
• 𝐻𝑔 = 11875 Nm = 11.875 KJ

Prof Sumit Suresh Malusare,FAMT,Ratnagiri

Thank You
Prof Sumit S Malusare
Assistant Professor
Finolex Academy Of Management & Technology, Ratnagiri
sumit.malusare@famt.ac.in
9403098168

Prof Sumit S Malusare,FAMT,Ratnagiri