ME 571P

MACHINE DESIGN 2
BRAKES
1

A brake is a device by means of which artificial frictional resistance is
applied to a moving machine member, in order to retard or stop the
motion of a machine.
In the process of performing this function, the brake absorbs either
kinetic energy of the moving member or potential energy given
up by objects being lowered by hoists, elevators etc.
The energy absorbed by brakes is dissipated in the form of heat.
This heat is dissipated in the surrounding air (or water which is
circulated through the passages in the brake drum) so that excessive
heating of the brake lining does not take place.
The major functional difference between a clutch and a brake is that
a clutch is used to keep the driving and driven member moving
together, whereas brakes are used to stop a moving member or
to control its speed.
2

ENERGY ABSORBED BY A BRAKE
The energy absorbed by a brake depends upon the type of motion of
the moving body.
The motion of a body may be either
1. pure translation or
2. pure rotation or
3. a combination of both translation and rotation.
1. When the motion of the body is pure translation.
( )
2
1 1 2
2
2
2
1 1
2 1
2
1
, 0 such that brake, by the absorbed be must t energy tha The
2
1
on, translati of energy kinetic of change The
body the of velocity final body; the of velocity initial
body; the of mass where motion, in body a Consider
mv E v
v v m E
v v
m
= =
=
= =
=
3

2. When the motion of the body is pure rotation.
( )
2
1 2
2
2
2
2
1 2
2
1
2
1

, 0 such that brake, by the absorbed be must t energy tha The
2
1
rotation, of energy kinetic of change The
body the of locity angular ve final
in body the of locity angular ve initial
inertia; of moment mass where
body, rotating a Consider
e
e
e e
e
e
I E
I E

s
rad
I
=
=
=
=
=
=
4

3. When the motion of the body is a combination of translation and
rotation.
Consider a body having both linear and angular motions, e.g. in the
locomotive driving wheels and wheels of a moving car.


Sometimes, the brake has to absorb the potential energy given up by
objects being lowered by hoists, elevators etc. Consider a body of
mass m is being lowered from a height h
1
to h
2
by applying the
brake.
2 1
brake, by the absorbed be energy to kinetic Total
E E E + =
( )
mgvt t
v v
mg E
v v
h h mg E
=
|
.
|

\
|
+
=
=
2
applied, is brake after the and before mass
the of s velocitie the are and If
energy, potential in change the Therefore
2 1
3
2 1
2 1 3
3 2 1
2 1
energy, total the Thus,
n applicatio brake of time

2

ity mean veloc
: where
E E E E
t
v v
v
+ + =
=
+
= =
5

( )
( )
dNt
E
F t dN F E
t dN F
t
N N
N
N
N
d
F
t t
t
t
t
t
t
= =
=
=
+
=
=
=
=
=
force frictional by the done work the
to equal be must brake by the absorbed be energy to total The

seconds in force frictional or braking by done work The
drum brake of speed mean
2
applied is brake after drum brake the of speed
applied is brake before drum brake the of speed
drum brake of diameter
drum brake the of surface contact at the ly tangential
acting force frictional or force braking tangential Let
2 1
2
1
6

drum brake the of radius : where
2
brake, by the absorbed be must which torque The
rest. to comes load
when the is that , 0 when maximum is value Its . time braking the
on and velocity final upon the depends of magnitude The
2
2
=
|
.
|

\
|
= =
=
r
d
F r F T
v t
v F
t t
t
7

Heat to be Dissipated during Braking
The energy absorbed by the brake and transformed into heat must be
dissipated to the surrounding air in order to avoid excessive temperature
rise of the brake lining.
The temperature rise depends upon the mass of the brake drum, the
braking time and the heat dissipation capacity of the brake.
When the temperature increases, the coefficient of friction decreases
which adversely affect the torque capacity of the brake.
At high temperature, there is a rapid wear of friction lining, which
reduces the life of lining.
Therefore, the temperature rise should be kept within the permissible
range.
The highest permissible temperatures recommended for different brake
lining materials are given as follows :
1. For leather, fibre and wood facing = 65 70C
2. For asbestos and metal surfaces that are slightly lubricated = 90 105C
3. For automobile brakes with asbestos block lining = 180 225C
8

Since the energy absorbed (or heat generated) and the rate of wear
of the brake lining at a particular speed are dependent on the normal
pressure between the braking surfaces, therefore it is an important
factor in the design of brakes.
The permissible normal pressure between the braking surfaces
depends upon the material of the brake lining, the coefficient of
friction and the maximum rate at which the energy is to be absorbed.
9

absorbed energy potential total
absorbed energy kinetic total : where
as, obtained be also may generated heat The
drum, brake the of velocity peripheral
surfaces, contact the of area projected
surfaces, braking e between th pressure normal
surfaces, contact on the acting force normal
friction of coeff.
or watts ,
generated, heat or the absorbed energy The
2
2
=
= + =
=
=
=
=
=
= = =
P
K P K g
N
N g
E
E E E H
s
m
v
m A
m
N
p
N R
f
s
J
fpAv v fR H E
1
0

( )
( )
( )
e. approximat quite are H for s expression above The
C 200 for 44 to up increase
and C 40 for 29.5 order the of maybe
in surface radiating of area
in air g surroundin the and
surface radiating exposed e between th rence temp.diffe
er, transf
heat of coeff. or factor n dissipatio heat : where
as estimated be may , dissipated heat The
d
2 1
2
2 1
2
2
2 1
2
2 1
=

=

=

=

=
=
t t
C m
W
t t
C m
W
C
m A
C
t t
C m
W
C
t t CA H
H
r
r d
d
1
1

C kg-
J
c
m
C t
J H
mc
H
t
g
g

=
=
= A
=
=
in drum brake the of material for the heat specific
kg in drum brake of mass
in drum the of rise temp.
in brake by the generated heat : where
by, given is drum brake the of ture in tempera rise The
rise. to re temperatu its causing
drum brake by the absorbed is heat remaining the air while g surroundin in the
dissipated y immediatel is generated heat the of 25% - 10 that found been has It
1
2

In brakes, it is very difficult to precisely calculate the temperature
rise.
In preliminary design analysis, the product pv is considered in place
of temperature rise.
The experience has also shown that if the product pv is high, the rate
of wear of brake lining will be high and the brake life will below.
Thus the value of pv should be lower than the upper limit value for
the brake lining to have reasonable wear life.
The following table shows the recommended values of pv as
suggested by various designers for different types of service.
1
3

Sample Problem 1
A 1100-kg car is moving down the hill at a slope of 1: 7 at 60 km / h.
It is to be stopped in a distance of 50 m. If the diameter of the tire is
600 mm, determine the average braking torque to be applied to stop
the vehicle, neglecting all the frictional energy except for the brake. If
the friction energy is momentarily stored in a 20 kg cast iron brake
drum, What is average temperature rise of the drum? The specific
heat for cast iron may be taken as 520 J / kgC.
Determine, also, the minimum coefficient of friction between the tires
and the road in order that the wheels do not skid, assuming that the
weight is equally distributed among all the four wheels.
C kg
J
c
kg; m; m . r m . mm m; d
;
s
m
.
h
km
; v kg; slope m
b
car

=
= = = = =
= = = =
520
20 3 0 6 0 600 50 travelled distance
67 16 60 7 : 1 1100
: Given
1
4

( )( )
( )( )
( )( ) m N r F T
N
E
F
dNt
E
F
m N E E E
m N E
m h mgh E
m N mv E
tire t B
t
t
P K
P
P
K
= = =
= = =
=
= + =
=
=
|
.
|

\
|
=
=
|
.
|

\
|
= = =
= = =
1379.505 3 . 0 4598.35 torque, braking average The
4598.35
50
229917.47
travelled distance
force braking tangential
229917.47
brake by the absorbed be energy to car the of energy Total
77078.57
7
50
81 . 9 1100
7
50
7
1
50 slope x travelled distance
: car the of energy potential The
152838.9 67 . 16 1100
2
1

2
1
: car the of energy kinetic The
2
2
t
1
5

( )
( )( ) | |
43 . 0
81 . 9 1100 4598.35
car the of weight surfaces
contact on the acting force normal ;
drum brake the of surface contact at the ntially tange
acting force frictinal the also is
: road and tire e between th friction of t coefficien Minimum
11 . 22
520 20
229917.47
drum brake the of rise re temperatu average The
=
=
= =
= =
=
=
|
.
|

\
|

= A
= = A
f
f
mg
R fR F
F
C
C kg
J
kg
J
t
E H
c m
H
t
N N t
t
g
b
g
1
6

Sample Problem 2 [prob.1/p.968]
A flywheel of mass 100 kg and radius of gyration 350 mm is rotating at
720 rpm. It is brought to rest by means of a brake. The mass of the
brake drum assembly is 5 kg. The brake drum is made of cast iron
having specific heat 460 J / kgC. Assuming that the total heat
generated is absorbed by the brake drum only, calculate the
temperature rise. [Ans. 15.14C]
mc
H
t
mk I
H I E
g
g
=
=
= =
2
2
1
2
1
e
1
7

MATERIALS FOR BRAKE LINING
The material used for the brake lining
1. should have high coefficient of friction with minimum fading. In other
words, the coefficient of friction should remain constant over the entire
surface with change in temperature.
2. should have low wear rate.
3. should have high heat resistance.
4. should have high heat dissipation capacity.
5. should have low coefficient of thermal expansion.
6. should have adequate mechanical strength.
7. should not be affected by moisture and oil.
1
8

1
9

TYPES OF BRAKES
1. Hydraulic brakes e.g. pumps or hydrodynamic brake and fluid
agitator,
2. Electric brakes e.g. generators and eddy current brakes, and
3. Mechanical brakes.

The hydraulic and electric brakes cannot bring the member to rest
and are mostly used where large amounts of energy are to be
transformed while the brake is retarding the load such as in
laboratory dynamometers, high way trucks and electric locomotives.
These brakes are also used for retarding or controlling the speed of a
vehicle for down-hill travel.
2
0

MECHANICAL BRAKES
Radial brakes. In these brakes, the force acting on the brake drum is in
radial direction. The radial brakes may be sub-divided into external
brakes and internal brakes. According to the shape of the friction
element, these brakes may be block or shoe brakes and band brakes.
Axial brakes. In these brakes, the force acting on the brake drum is in
axial direction. The axial brakes may be disc brakes and cone brakes.
The analysis of these brakes is similar to clutches.
2
1

Single Block or Shoe Brake
It consists of a block or shoe which is pressed against the rim of a
revolving brake wheel drum.
The block is made of a softer material than the rim of the wheel.
This type of a brake is commonly used on railway trains and tram cars.
The friction between the block and the wheel causes a tangential
braking force to act on the wheel, which retard the rotation of the wheel.
The block is pressed against the wheel by a force applied to one end of
a lever to which the block is rigidly fixed as shown below.
The other end of the lever is pivoted on a fixed fulcrum O.
2
2

wheel the and block the of surface contact at the acting
force frictional or the force braking tangential
friction of t coefficien
block the of surface contact the of angle 2
wheel brake the of radius
wheel on the block the pressing force normal
lever the of end at the applied force Let
=
=
=
=
=
=
t
N
F
f

r
R
P
2
3

r fR r F T
fR F
N t B
N t
= =
=
<
torque, Braking
uniform. is wheel the and block the
between pressure normal that is assumption , 60 2 If u
Case 1
When the line of action of tangential braking force (F
t
) passes through
the fulcrum O of the lever, and the brake wheel rotates clockwise.
x
fPlr
r fR T
x
Pl
R Pl x R
M
N B
N N
O
= =
= =
= E 0
2
4

Case 2
When the line of action of the tangential braking force (F
t
) passes
through a distance a below the fulcrum O, and the brake wheel rotates
clockwise or counterclockwise.








( )
fa x
fPlr
r fR T
fa x
Pl
R
Pl a fR x R Pl a F x R
M
N B
N
N N t N
O
+
= =
+
=
= + = +
= E 0
( )
fa x
fPlr
r fR T
fa x
Pl
R
a fR Pl x R a F Pl x R
M
N B
N
N N t N
O

= =

=
+ = + =
= E 0
2
5

Case 3
When the line of action of the tangential braking force passes through a
distance a above the fulcrum, and the brake wheel rotates clockwise or
counterclockwise.







fa x
fPlr
r fR T
fa x
Pl
R
a fR Pl a F Pl x R
M
N B
N
N t N
O

= =

=
+ = + =
= E 0
( )
fa x
fPlr
r fR T
fa x
Pl
R
Pl a fR x R Pl a F x R
M
N B
N
N N t N
O
+
= =
+
=
= + = +
= E 0
2
6

Equations for R
N
for case 2b and case 3a are identical.

The frictional force helps to apply the brake. Such type of brakes are
said to be self energizing brakes.
When the frictional force is great enough to apply the brake with no
external force, then the brake is said to be self-locking brake.
From the above expression, we see that if x fa, then P will be
negative or equal to zero.
This means no external force is needed to apply the brake and
hence the brake is self locking.
Therefore the condition for the brake to be self locking is
But the brake should be self-energizing and not the self-locking.
In order to avoid self-locking and to prevent the brake from grabbing,
x is kept greater than fa.



( )a fR Pl x R
N N
+ =
. fa x s
2
7

When a single block or shoe brake is applied to a rolling wheel, an
additional load is thrown on the shaft bearings due to heavy normal
force (R
N
) and produces bending of the shaft. In order to overcome
this drawback, a double block or shoe brake.

( ) u sin 2
shoe of length projected x shoe of width
pressure bearing
shoe or block the of area bearing projected Let
r w A
A
A
R
p
p
A
b
b
b
N
b
b
b
=
=
=
=
=
2
8

Pivoted Block or Shoe Brake
When the angle of contact is less than 60, then it may be assumed that
the normal pressure between the block and the wheel is uniform.
But when the angle of contact is greater than 60, then the unit pressure
normal to the surface of contact is less at the ends than at the centre.
In such cases, the block or shoe is pivoted to the lever as shown,
instead of being rigidly attached to the lever.
This gives uniform wear of the brake lining in the direction of the applied
force.
These brakes have more life and may provide a higher braking torque.
friction coeff.of actual
2 sin 2
sin 4

friction coeff.of equivalent '
'
) 60 2 when (i.e. brake shoe or block
pivoted a for torque braking The
=
+
=
=
= =
>
f
f
f
r R f r F T
N t B
u u
u
u

2
9

Sample Problem 3 [prob.2/p.969]
A single block brake, as shown, has the drum diameter 250 mm. The
angle of contact is 90 and the coefficient of friction between the drum
and the lining is 0.35. If the torque transmitted by the brake is 70 N-m,
find the force P required to operate the brake.
Also, determine the location of the pivot or fulcrum to make the brake
self locking for the given rotation of the brake drum.
m N ; T . f
;
mm; r mm d
B
= =
= =
= =
70 35 0
45 90 2
125 250
: Given
u
3
0

( )
( ) ( ) ( )
( ) ( )
N P
P
f
F
R
F P R
M
N F r F T
t
N
t N
O
t t B
3 . 692
25 560 400 200
385 . 0
560
'
25 400 200
0
560
125
1000 70
=
+ =
=
+ =
= E
= = =
( )
385 . 0
2
sin
4
2
4
sin 35 . 0 4
'
4 180
45 ;
2 sin 2
sin 4
'
, 60 2 Since
=
+
|
.
|

\
|
|
.
|

\
|
=
=
|
.
|

\
|

=
+
=
>
t t
t
t t
u
u u
u
u
f
f
f
3
1

( ) ( ) ( )
( ) ( )
9.5mm 51
560 0 200
385 . 0
560
'
; 400 200
0
or
5 . 519
385 . 0
200
'
'
locking, - self be to brake For the
=
+ =
= + =
= E
= = = s
a
a
f
F
R a F P R
M
mm
f
x
a a f x
t
N t N
O
3
2

Sample Problem 4 [example 25.5/p.939]
A rope drum of an elevator having 650 mm diameter is fitted with a brake
drum of 1 m diameter. The brake drum is provided with four cast iron brake
shoes each subtending an angle of 45. The mass of the elevator when
loaded is 2000 kg and moves with a speed of 2.5 m / s. The brake has a
sufficient capacity to stop the elevator in 2.75 metres. Assuming the
coefficient of friction between the brake drum and shoes as 0.2, find: 1.
width of the shoe, if the allowable pressure on the brake shoe is limited to
0.3 N/mm
2
; and 2. heat generated in stopping the elevator.
2
. .
3 . 0 2 0 ; 75 . 2
; 5 . 2 ; 2000 5 . 22 45 2 4
; 500 1 325 . 0 325 650
: Given
mm
N
; p . f m h
s
m
v kg ;m ; n
mm r m m; d mm r mm d
b
drum elev drum elev
= = =
= = = = =
= = = = =
u
3
3

( )
( )
( )
( )
( )
| |
N
f
F
R
f
n
F
F
N
r
T
F
N-m Wr T
N W
N ma F
s
m
a
v ah v v
a
t
N
t
t
t
elev.drum
a
f f i
T
T
17787.25
2 . 0
45 . 3557
shoe each on load normal
' for compute to need no , therefore , 60 45 shoe each for 2
3557.45N
4
14229.8
shoe each on force tangential
14229.8
5 . 0
9 . 7114
drum brake on the force tangential
7114.9 325 . 0 21892 drum rope on the torque
21892 2272 9.81 2000 rope on the load total
2272 136 . 1 2000
136 . 1
75 . 2 2
5 . 2
0 ; 2
rope the of on accelerati
2
2
2 2
= = = =
< =
= = = =
= = = =
= = = =
= + = =
= = =
= =
= =
=
u
3
4

( )
( )
( )( ) ( )
( )( ) ( )( ) kJ m N
mgh mv E E H
H
mm mm w
w
r w
R
A
R
p
r w A
P K g
g
N
b
N
b
b
205 . 60 60205 75 . 2 81 . 9 2000 5 . 2 2000
2
1

2
1
brake by the
absorbed energy total elevator the stopping in generated heat
155 154.9 shoe each of width
5 . 22 sin 500 2
17787.25
3 . 0
sin 2
shoe each on pressure bearing
sin 2 shoe each of area bearing projected
2
2
= = + =
+ = + =
= =
~ = =

=
= = =
= =
3
5

HW Problem: [prob.3/p.969]
A single block brake, as shown in the
figure, has a drum diameter of 720 mm. If
the brake sustains 225 N-m torque at 500
rpm; find :
(a) the required force (P) to apply the
brake for clockwise rotation of the drum;
(b) the required force (P) to apply the
brake for counter clockwise rotation of the
drum;
(c) the location of the fulcrum to make the
brake self-locking for clockwise rotation of
the drum; and
The coefficient of friction may be taken as
0.3.
[Ans. 805.4 N ; 861 N; 1.2m]
3
6

Double Block or Double Shoe Brake
When a single block brake is applied to a rolling wheel, and additional
load is thrown on the shaft bearings due to the normal force (R
N
).
This produces bending of the shaft. In order to overcome this drawback,
a double block or shoe brake is used.
It consists of two brake blocks applied at the opposite ends of a
diameter of the wheel which eliminate or reduces the unbalanced force
on the shaft.
The brake is set by a spring which pulls the upper ends of the brake
arms together. When a force P is applied to the bell crank lever, the
spring is compressed and the brake is released.
This type of brake is often used on electric cranes and the force P is
produced by an electromagnet or solenoid. When the current is switched
off, there is no force on the bell crank lever and the brake is engaged
automatically due to the spring force and thus there will be no downward
movement of the load.
In a double block brake, the braking action is doubled by the use of two
blocks and the two blocks may be operated practically by the same force
which will operate one.
3
7

3
8

( )
blocks two on the forces braking ,
is torque Braking
2 1
2 1
=
+ =
t t
t t B
F F
r F F T
Sample Problem 5 [prob.4/p.969]
The layout and dimensions of a double shoe brake is shown below. The
diameter of the brake drum is 300 mm and the contact angle for each
shoe is 90. 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 N-m.
Also determine the width of the brake shoes, if the bearing pressure on
the lining material is not to exceed 0.28 N/mm
2
.
2
28 . 0
; 30 4 0
45 90 2
150 300
: Given
mm
N
p
m N ; T . f
;
mm; r mm d
b
B
=
= =
= =
= =
u
3
9

4
0

( )
44 . 0
2
sin
4
2
4
sin 4 . 0 4
'
4 180
45 ;
2 sin 2
sin 4
' , 60 2
shoe other on the force braking and reaction normal and
shoe one on force braking and reaction normal and
brake set the to necessary force spring
2
1
2
1
=
+
|
.
|

\
|
|
.
|

\
|
=
=
|
.
|

\
|

=
+
= >
=
=
=
t t
t
t t
u
u u
u
u
f
f
f
F R
F R
S
t N
t N
4
1

( )
( ) ( ) ( )
( ) ( ) ( )
S F
F
F
S
f
F
R F R S
M
t
t
t
t
N t N
o
0.7182
150 225
44 . 0
475
'
; 150 225 475
shoe hand right for the 0
1
1
1
1
1
1 1
=
+ =
= + =
= E
( )
( ) ( ) ( )
( ) ( ) ( )
S F
F
F S
f
F
R R F S
M
t
t
t
t
N N t
o
1.3145
225
44 . 0
150 475
'
; 225 150 475
shoe hand left for the 0
2
2
2
2
2
2 2
=
= +
= = +
= E
( )
( )( )
N S
S S
r F F m N T
t t B
4 . 98
150 1.3145 0.7182
30
2 1
=
+ =
+ = =
4
2

( )
( )
( )
( )( )( )
mm mm b
b
r b
R
A
R
p
R
R R
N
f
S
f
F
R
N
f
S
f
F
R
b
N
b
N
b
N
N N
t
N
t
N
5 95 . 4
45 sin 150 2
293.97
28 . 0
sin 2
. force normal maximum on the
based be should shoe of design , Since
293.97
44 . 0
4 . 98 1.3145
'
1.3145
'
160.62
44 . 0
4 . 98 0.7182
'
0.7182
'
: shoes brake of width For
2 2
2
1 2
2
1
2
1
~ =

=
= =
>
= = = =
= = = =
=
*Study Example 25.7, page 942
Simple Band Brake
A band brake consists of a flexible band of leather, one or more ropes,
or a steel lined with friction material, which embraces a part of the
circumference of the drum.
4
3

A band brake shown above is called a simple band brake in which one
end of the band is attached to a fixed pin or fulcrum of the lever while
the other end is attached to the lever at a distance b from the fulcrum.
When a force P is applied to the lever at C, the lever turns about the
fulcrum pin O and tightens the band on the drum and hence the brakes
are applied.
The friction between the band and the drum provides the braking force.
4
4

4
5

( )
( ) band the of thickness g considerin
band the of thickness neglecting
drum, on the torque Braking
, tensions the of ratio Limiting
2

drum the of radius effective
band the of thickness
drum the of radius
drum and band e between th friction of coeff.
drum on the band the of embrace or lap of angle
band the of side slack in the tension
band the of side tight in the tension : Let
2 1
2 1
2
1
2
1
=
=
=
+ =
=
=
=
=
=
=
=
e B
B
f
e
r T T T
r T T T
e
T
T
t
r
r
t
r
f
T
T
u
u
4
6

b T Pl
o
1
: fulcrum about the moment Taking
= b T Pl
o
2
: fulcrum about the moment Taking
=
4
7

b T Pl
o
2
: fulcrum about the moment Taking
=
b T Pl
o
1
: fulcrum about the moment Taking
=
Sometimes the brake band is attached to the lever as shown.
4
8

band the of thickness
band the of width :
1
=
= =
t
w wt S T
t
If the permissible tensile stress (S
t
) for the material of the band is known,
then maximum tension in the band is given by
The width of band (w) should not exceed 150 mm for drum diameter (d )
greater than 1 metre and 100 mm for drum diameter less than 1 metre. The
band thickness (t) may also be obtained by using the empirical relation, t =
0.005 d
Sample Problem 6
The drum of a simple band brake is 450 mm. The band embraces 3/4th of
the circumference of the drum. One end of the band is attached to the
fulcrum pin and the other end is attached to a pin B as shown below. The
band is to be lined with asbestos fabric having a coefficient of friction 0.3.
What width of steel band of 2.5 mm thick is required for this brake if the
maximum tensile stress is not to exceed 50 MPa ?
Is the width of band as computed based on its yield strength safe for an
allowable bearing pressure for the brake lining of 0.21 N/mm
2
.
4
9

( )
2
50 ; 5 . 2 3 0
2
3
270 360
4
3
225 450
: Given
mm
N
S mm ; t . f

mm; r mm d
band
t
= = =
= = =
= =
t
5
0

( )
( ) ( )( )
( ) N T
N T
T
o
T T
e e
T
T
f
7194.6 1750 1112 . 4
1750
75 450 250 75
: fulcrum about the moment Taking
1112 . 4
1
2
2
2 1
2
3
3 . 0
2
1
= =
=
+ =
=
= =
t
u
( )
mm w
t
w wt S T
t
6 . 57
5 . 2 50
6 . 7194
band the of thickness
band the of width :
1
= =
=
= =
5
1

( )
( )
( )( )( )
. 6 57 !
21 . 0 297 . 0
6 . 57 3 . 1060 3 . 0
1750 - 7194.6
3 . 1060
360
270
450
360
length
band the of width x
drum th the contact wi in band the of length area bearing
band on the acting force normal
21 . 0
2 2
2 1
2
mm . than e greater w should b safe not
mm
N
mm
N
p
mm d
A
f
T T
R
mm
N
p
A
R
p
b
b
N
b
b
N
b

> = =
=
|
.
|

\
|
=
|
.
|

\
|

=
= =

= =
s =
t
u
t
Differential Band Brake
In a differential band brake, as shown below, the ends of the band are
joined at A and B to a lever AOC pivoted on a fixed pin or fulcrum O.
It may be noted that for the band to tighten, the length OA must be
greater than the length OB.
In this type of brake, the tension in the band assists in applying the
brake.
5
2

5
3

b T a T Pl
a T b T Pl
o
1 2
2 1
: fulcrum about the moment Taking
=
= +
b T a T Pl
a T b T Pl
o
2 1
1 2
: fulcrum about the moment Taking
=
= +
When the frictional force helps to apply the brake, it is said to be self
energizing brake.
In case of differential band brake, we see from equations above that the
moment T
1
b and T
2
b helps in applying the brake (because it adds to the
moment Pl) for the clockwise and anticlockwise rotation of the drum
respectively.
5
4

When the force P is negative or zero, then brake is self locking. Thus
for differential band brake and for clockwise rotation of the drum, the
condition for self- locking is
T
2
.a T
1
.b or T
2
/T
1
b / a
and for anticlockwise rotation of the drum, the condition for self-locking is
T
1
.a T
2
.b or T
1
/T
2
b / a
Notes: The condition for self-locking may also be written as follows.
For clockwise rotation of the drum,
T
1
.b T
2
.a or T
1
/T
2
a / b
and for anticlockwise rotation of the drum,
T
2
.b T
1
.a or T
2
/T
1
a/b
5
5

In the above figures, when the length OB is greater than OA, then the
force P must act in the upward direction in order to apply the brake. The
tensions in the band, i.e. T
1
and T
2
will remain unchanged.
5
6

Sometimes the brake band is attached to the lever as shown.
In the above figures, when the length OB is greater than OA, then the force
(P) must act downward in order to apply the brake. The position of tensions
T
1
and T
2
will remain unchanged.
Sample Problem 7 [example 25.10/p.953]
A differential band brake, as shown in the figure below, has an angle of
contact of 225. The band has a compressed woven lining and bears
against a cast iron drum of 350 mm diameter. The brake is to sustain a
torque of 350 N-m and the coefficient of friction between the band and
the drum is 0.3. Find : 1. the necessary force (P) for the clockwise and
anticlockwise rotation of the drum; and 2. The value of OA for the brake
to be self locking, when the drum rotates clockwise.
5
7

3 0 ; 350
175 350 ; 225
: Given
. f m N T
mm; r mm d
b
= =
= = =
5
8

( )
( ) ( )
( )
( ) ( ) ( )
( ) ( )
N P
T T P
M
N T
N T
T T
r T T T
T T
e e
T
T
o
B
f
64.63
500
35 68 . 2889 150 889.68
35 150 500
0
68 . 2889 889.68 248 . 3
889.68
175 248 . 3 1000 350
248 . 3
248 . 3
: drum of rotation clockwise For
1 2
1
2
2 2
2 1
2 1
180
225 3 . 0
2
1
=

=
=
= E
= =
=
=
=
=
= = =
(

|
.
|

\
| t
u
( ) ( ) ( )
( ) ( )
N P
T T P M
o
804.63
500
35 889.68 150 68 . 2889
35 150 500 0
: drum of rotation ise anticlockw For
2 1
=

=
= = E
5
9

( ) ( ) ( )
( ) ( )
( )
mm OA
OB T OA T
P
OB T OA T P
M
o
7 . 113
889.68
35 68 . 2889
0 to equal be must locking, - self be to brake For the
500
0
: drum of rotation clockwise For
1 2
1 2
= =
=
=
= E
HW Problem [prob.7/p.970]
A differential band brake is shown in the figure below. The diameter of
the drum is 800 mm. The coefficient of friction between the band and
the drum is 0.3 and the angle of embrace is 240. When a force of 600
N is applied at the free end of the lever, find for the clockwise and
anticlockwise rotation of the drum: 1. the maximum and minimum forces
in the band; and 2. the torque which can be applied by the brake.
[Ans. 176 kN, 50 kN, 50.4 kN-m ; 6.46 kN, 1.835 kN, 1.85 kN-m]
6
0