MECHANICAL BRAKING SYSTEM

Submitted by
Regikumar.K
3rd year mechanical

INTRODUCTION
Mechanical brakes are assemblies
consisting of mechanical elements
for the slowing or stopping of
shafts in equipment drives.They
use levers or linkages to transmit
force from one point to another.
Braking slows or stops the
movement of the coupled shafts.

Brake System Principles

Kinetic Energy
Mass
Weight
Speed
Inertia and
Momentum

TYPES OF MECHANICAL BRAKE

Band brakes
Drum brakes
Disc breaks
. Cone brakes

Band brakes, the simplest brake configuration,

have a metal band lined with heat and wear
resistant friction material
Drum brakes, which are commonly used on
automobile rear wheels, work when shoes
press against a spinning surface called a drum
Disc brakes are constructed of brake pads, a
caliper, and a rotor. During operation, the
brake pads are squeezed against the rotor
Cone brakes are made with a cup and a cone,
which is lined with heat and wear resistant
material. During actuation,the cone is pressed
against the mating cup surface.

MECHANICAL BRAKES

TYPICAL SYSTEM

Disk Brake
It Consists of two Brake
pads
Works similar to Bicycle
Brake where two rubber
pads rub against the
wheel rim.

Disc Brake Parts

Calipers (4)
Brake Pads
Rotors (3)

Disc Brake Operation

A piston inside the caliper
pushes the brake pads toward
each other
The rotor is located between
the pads
The squeezing effect causes
friction which slows the car

Disc Brake Problems

Rotor warp from over tightened
wheels which causes pedal vibration
Calipers can stick causing the brake
pads to drag
Rear wheel disc brake parking brake
mechanism can become stuck

HYDRAULIC DISC BRAKES

Disc mech bike

Servicing Disc Brakes

Loosen the caps on the mater cylinder
Use a large screwdriver or pry bar to force
the piston back into the caliper
Remove the bolts or clips that hold the
caliper to the mounting
Remove the caliper and remove the pads
Check the condition of the rotor, a worn or
grooved rotor will need machining

Installing New Disc Brakes

Put anti-squeal compound on the back of the pads

Put new pads into the caliper
Install the caliper into the mounting bracket
Install the clips or bolts
Press on the brake pedal several times until it is
firm
Check the master cylinder fluid level and tighten
caps

Disc Brake Caliper Assembly

Caliper Types
There are 2 types of Calipers
Fixed
Calipers are disc brakes that use a caliper that is
FIXED in position and does not slide. They have
pistons on both sides of the disc. There may be
2 or 4 pistons per caliper

Floating
Much more common
Single Piston
Easier to work with
On inboard side of caliper

Fixed Caliper
Applies two
pistons to
opposite sides of
rotor
Caliper stays
stationary
Disc Brakes
require higher
hydraulic pressure

Sliding Caliper
Applies pressure
to two pads on
opposite sides of
rotor
Caliper
Sliding
Fixed

Friction Material
exposed to air

Drum Brakes
Expanding shoes
create force on the
inner surface of the
drum
Used on the rear of
some trucks and
SUVs
Self-energizing design
requires less
activation force
Require periodic
adjustment

Drum Brake System

Drum Brake Parts

Brake Shoes (5, 12)
Backing Plate (14)
Return Springs (3,
13)
Hold Down Springs
(11)
Self Adjusting Parts
(4, 7, 8, 10)
Wheel Cylinder
Parking Brake (6, 9)
Drums

Drum Brake Operation

The wheel cylinder forces the brake shoes
apart
The shoes are forced against a drum
The friction changes rotary energy into heat
energy which slows the car
The harder the shoes are forced apart, the
faster the car stops

Drum Brake Problems

Overheating the drums can cause them
to warp or over expand (brake fade)
Springs can stretch over time causing
the brakes to drag
Wheel cylinders can leak ruining the
shoes
Parking brake cables can seize

Servicing Drum Brakes

Using a brake tool, remove the return
springs
Remove the hold down springs
Remove the self adjuster rod
Note where the longer brake shoe is located
Remove the parking brake cable
Remove the brake shoes together

Reinstalling Drum Brakes

Transfer all the self adjusting parts to
the new shoes
Install on the backing plate
Install the parking brake cable and self
adjuster rod
Install the hold down and return springs
Install the drum and adjust till the shoes
just hit the drum