B R A K E S

Brake is a machine element for applying

friction to moving surface to slow it down or bring it to
rest. It is a device used to slow and stop a rotating
wheel and thus a moving vehicle. The friction created
by the rubbing together of two objects generates a
large amount of heat. A brake system must be capable
of dissipating the heat as rotating wheels slow,
because excess heat can cause the brakes to lose their
grip and fail.
Factors That Affects The Capacity of The Brakes

1. The unit pressure between the braking surfaces.

2. The coefficient of friction between the braking

surfaces.

3. The peripheral velocity of the brake drum.

4. The projected area of the friction surfaces.

5. The ability of the brake to dissipate heat equivalent

to the energy being absorbed.
 Factors That Affect The Brake Lining

1. Low wear rate.

2. High heat resistance.

3. High heat dissipation capacity.

4. Low coefficient of thermal expansion.

5. Adequate mechanical strength.

6. Should not affected by moisture and oil.

7. High coefficient of friction with minimum fading.

 BRAKE LINING

This is a crucial component of brake systems

in vehicles, responsible for providing friction
against the brake drums or rotors to slow
down or stop the vehicle. The best materials
used for brake linings typically possess
characteristics such as high friction
coefficient, good thermal stability, wear
resistance, and minimal brake fade.
Commonly used materials for brake
linings:

1. Organic (Non-Asbestos Organic - NAO):

 Made from a mixture of various organic

materials such as rubber, glass, Kevlar, and
resins.
 Provides smooth braking performance with low
noise levels.
 Environmentally friendly and less abrasive to
brake rotors.
 Typically used in light-duty vehicles.
2. Semi-Metallic:

 Combines organic materials with metal fibers

or particles such as steel, copper, or brass.
 Offers improved heat dissipation and better
performance under heavy braking conditions.
 Suitable for both light and heavy-duty vehicles.
 May produce more brake dust and noise
compared to organic linings.
3. Ceramic:

 Composed of ceramic fibers, filler materials, and

bonding agents.
 Exhibits excellent heat resistance and low wear
rates, resulting in longer lifespan.
 Provides consistent braking performance across
a wide range of temperatures.
 Minimizes brake dust and noise, contributing to
cleaner wheels and quieter braking.
 Typically used in high-performance vehicles and
luxury cars.
4. Carbon Fiber:

 Incorporates carbon fibers, resins, and other

reinforcing materials.
 Offers exceptional thermal stability and
resistance to fade even under extreme
conditions.
 Provides strong initial bite and consistent
braking performance.
 Lightweight and durable, contributing to
improved fuel efficiency and longevity.
 Commonly found in high-performance
vehicles and racing applications.
Note:

The choice of brake lining material depends on

factors such as vehicle type, driving conditions,
performance requirements, and budget considerations.
It's essential to select brake linings that are compatible
with the vehicle's braking system and meet safety
standards to ensure reliable and efficient braking
performance. Additionally, regular inspection and
maintenance of brake components are necessary to
ensure optimal functionality and safety on the road.
B - A T T E R Y
L - I G H T S
O - I L
W - A T E R
B - R A K E
A - I R
G - A S
E - N G I N E
T - I R E
S - E L F
 TYPES OF BRAKES

1. Mechanical Brakes – band, block, shoe

and spot

2. Hydrodynamics Brakes – utilize fluid

friction

3. Electrical Brakes – utilize the strength

of electromagnetic
fields
 ANTI-LOCK BRAKING SYSTEM

An anti-lock braking system (ABS) is a safety

feature installed in modern vehicles to prevent the
wheels from locking up during braking, thereby
helping the driver maintain steering control during
emergency braking situations or when braking on
slippery surfaces. ABS works by modulating the
brake pressure to each wheel independently,
preventing the wheels from skidding and
maintaining traction with the road surface.
How ABS typically functions?
Wheel Speed Sensors: ABS utilizes sensors at
each wheel to monitor its speed. These sensors
send real-time data to the ABS control unit.

Control Unit: The ABS control unit processes

the information received from the wheel speed
sensors and determines if any wheel is about
to lock up.
 Modulator Valves: The control unit operates
modulator valves to adjust the brake pressure
to each wheel. If it detects a wheel locking
up, it reduces brake pressure momentarily
and then reapplies it, allowing the wheel to
continue rotating.

 Pulsating Brakes: The action of the ABS

causes the brakes to pulsate rapidly during
emergency braking, helping to prevent wheel
lockup while maintaining steering control.
 By preventing wheel lockup, ABS allows
the driver to maintain directional stability and
control of the vehicle during hard braking or
on slippery road surfaces such as wet, icy, or
gravel roads. This technology has become
standard in most vehicles produced today and
has significantly contributed to reducing
accidents and improving overall vehicle safety.
Band Brake
It is considered as the simplest of all brakes. It
may consist of a rope, belt, or flexible steel band acting
against the external surface of a cylindrical drum.
θ

R
F2

F1
Fa
a
L
 BAND BRAKES FORMULA

1. Tension ratio:
F1/F2 = efθ

2. Torque developed by the braking action

T = ( F1 – F2)R

3. Maximum unit pressure

Pmax = F1 / A = F1 / wR
4. Maximum allowable stress
Smax = F1 / A = F1 / wt

5. Actuating force
Fa = F2 (a) / L

Note: 1. For angles of contact greater than or equal

to 60 degrees use pivoted or movable
block.

2. For angles of contact below 60 degrees

fixed block may be used.
 Differential Brake
It is a type of brake that the tension in
the band assists in applying the brake.
θ

clockwise

ω
counterclockwise

F1

F2 b

Fa
a
L
 DIFFERENTIAL BRAKES FORMULA

1. Actuating Force (for clockwise rotation)

F1(a) – F2(b)
Fa =
L
Where:
Fa = actuating force
L = lever arm
a = distance from fixed point to F1
b = distance from fixed point to F2
F1 = force on the tight side
F2 = force on the slack side
2. Actuating Force (for counterclockwise rotation)

F2(b) – F1(a)
Fa =
L

Where:
Fa = actuating force
L = lever arm
a = distance from fixed point to F1
b = distance from fixed point to F2
F1 = force on the tight side
F2 = force on the slack side
 BLOCK BRAKES
It is a type of brake in which the block attached
to the operating lever is forced against the rotating
wheel. The frictional force produced by the block on the
wheel will retard the rotation of the wheel.
L

h Ff
Fa
A Fr

B ω
 BLOCK BRAKE FORMULA

1. The braking Torque

T = f Fr h
Where:
T = braking torque
f = coefficient of friction
h = effective moment arm of the friction
Fr = radial force

2. Torque for large angle of contact greater or equal

to 600

Pmax(w)(R)
T = (θ + sin θ)
2
Where:
T = braking torque
Pmax = maximum normal pressure between
block and drum
w = axial width of block
R = radius of the surface of the drum
θ = angle of contact

Note: 1. If θ is less than or equal to 60 degrees

uniform normal pressure between the drum
and the shoe may be assumed.
2. If θ is greater than 60 degrees the pressure
between the brake shoe and the drum can
not be considered anymore.
 BRAKE SHOE
It is a type of brake that provides uniform
contact between the lining and the wheel.

brake drum

Fa Fa

brake shoe

brake lining
 BRAKE SHOE FORMULA

1. Heat Dissipated in Brakes

H = f Fr V
Where:
H = heat dissipated
f = coefficient of friction
Fr = radial load
V = surface velocity
 SPOT BRAKE FORMULA

1. Braking Torque Capacity

T=2fFR
= 2 π f P r2 R
Where:
T = braking torque
f = coefficient of friction
F = radial load
R = radial distance
P = hydraulic pressure within the actuating
cylinders
r = radius of each hydraulic cylinder
 SAMPLE PROBLEMS

1. A band brake is installed on a drum rotating at 250

rpm and a diameter of 900 mm. The angle of
contact is 1.5π radians and one end of the brake
band is fastened to a fixed pin while the other end
to the brake arm 150 mm, from the fixed pin. The
coefficient of friction is 0.25 and the straight brake
arm is 1000 mm long and is placed perpendicular to
the diameter bisecting the angle of contact. The
power being absorbed is 50 KW. Compute the
actuating force and determine the width of the
band if the maximum tensile stress of steel band is
55 Mpa and 3 mm thick.
2. A differential band brake has an angle of contact, θ
equal to 280 degrees and is to sustain a torque of
7000 in-lbs. The band has a compressed woven lining
and bears against a cast iron drum of 14 inches
diameter. Coefficient of friction is 0.3 and other
dimensions are: L = 20 in.; a = 1 in. and b = 5 in.
Determine the necessary actuating force for both
clockwise and counterclockwise rotations.

3. A simple external block brake shown is fitted with a

cast iron brake shoe. The coefficient of friction is 0.3.
The braking torque is to be 3000 in-lb. Determine the
force required for both clockwise and counterclockwise
rotations . Where must the pivot be placed to make the
brake self-energizing with counterclockwise rotation?
What is the value of the energizing torque?