Brakes

A brake is a device used either to bring to rest a body which is in motion or to hold a body in a state of
rest or uniform motion against the action of external forces or couples. Actually the brake offers the
frictional resistance to the moving body and this frictional resistance retards the motion and the body
comes to rest. In this process, the kinetic energy of the body is absorbed by brakes.
Types of brakes
(a) Hydraulic brakes, (b) Electric brakes and (c) Mechanical brakes.
This chapter deals with mechanical brakes only. The following are the important types of mechanical
brakes:
(1) Simple block or shoe brake.
(a) Single block or shoe brake
(b) Double block or shoe brake
(2) Band brake.
(a) Simple band brake
(b) Differential band brake
(3) Band and block brake.

(1) Simple block or shoe brake

(a) Single block or shoe brake
It consists of a block or shoe which is pressed against a rotating drum as shown in fig (1). The block is
rigidly fixed to the lever. The force is applied to the lever; the block is pressed against the rotating drum.
Let P = Force applied at the lower end
r = Radius of the drum
μ = Coefficient of friction
RN = Normal reaction on the block
2θ = Angle made by contact
surface of the block at the
center of the drum
F* = Frictional force acting on
block = μ RN
TB = Braking torque. Fig (1)
When force (P) applied at the lever end, the block is pressed against the rotating drum. The block exerts
a radial force on the drum. The drum will exert a normal reaction (RN) on the block. Hence,
Radial force on the drum = RN
Assuming that the (RN) and (F* = μ RN) act at the mid-point of the block, we have
Braking torque on the drum = Frictional force * radius
Or TB  F *  r  RN  r ........(1)
Case 1. When the line of action of the frictional force (μ RN) is passing through the fulcrum (O) and the
drum rotates clockwise as shown in fig (1).

The forces acting on the block are: (i) RN (normal reaction), (ii) μ RN (frictional force) and (iii) P
(applied force). Taking moments about the fulcrum (O), we have
P L
RN  a  P  L  RN  [The frictional force passes through (O); hence its moment is zero]
a
P L
Substituting this value of (RN) in equation (1) we get TB     r ......(2)
a
Case 2. When the line of action of the frictional force (μ RN) is at a distance (b) below the fulcrum (O)
and the drum rotates clockwise as shown in fig (2).
1
Taking moments about (O), we get
P L
R N  a  R N  b  P  L  R N 
a  b 
Substituting this value of (RN) in equation (1) we get

  P Lr
TB  ......(3)
a  b 
If the drum is rotating in anticlockwise direction as
shown in fig (3) then the frictional force will also
acting in anticlockwise direction.

The moment of all forces acting on the block about

(O) will give, Fig (2)
P L
R N  a  P  L  R N  b  R N  ....... (4)
a  b 
Substituting this value in equation (1) we get
  P Lr
TB  ........ (5)
a  b 
From equation (4), the expression for the force (P)
required to apply the brake is obtained as
R a  b 
P N .
L
If a  b , then P will be negative or zero. This means
that no external force is required to apply the brake
and hence the brake is self-locking. Fig (3)
And if ( P  0) then the brake is self-energised.

So that, if P  0 it is a self locking brake and if P  0 it is self energized brake.

In actual practice the brake should be self-energised and not self-locking.

Case 3. When the line of action of the frictional force is at a distance (b) above the fulcrum (O) and the
drum rotates clockwise as shown in fig (4).
Taking the moments about (O), we get
P L
R N  a  R N  b  P  L  R N 
a  b 
Substituting this value of (RN) in equation (1) we get

  P Lr
TB  ........ (6)
a  b 
In this case also, the brake may be self-locking or Fig (4)
self-energised.
If the drum is rotating in anticlockwise direction as shown in fig (5), then the frictional force will also be
acting in anticlockwise direction.
2
Taking the moments of all forces about the fulcrum (O), we get

P L
R N  a  R N  b  P  L  R N 
a  b 
Substituting this value in equation (1) we get
  P Lr
TB  ........ (7)
a  b 
Note: For all the above expressions, (RN) and (μRN) are
assumed to be acting at the mid-point of the block. This is Fig (5)
true only if the angle made by contact surface of the
block at the center of the rotating drum is less than or
equal to (40º) (i.e. 2  40 ).
But if angle of contact is more than 40º, the normal pressure is less at the ends than at the center. In
 
that case, (μ) has to be replaced by an equivalent coefficient of friction   as given by
 4  sin  
   ........(8)
 2  sin 2 
Where μ = Actual coefficient of friction.
Notes:
(1) For case 1, self-locking of brake takes place if brake drum is rotating anticlockwise
direction.
(2) For case 2, brake will be self-locking if brake drum rotates clockwise.

(b) Double block or shoe brake

When a single block brake is pressed against a rotating drum, a
side thrust on the bearing of the shaft supporting the drum will
act due to normal reaction (RN). This produces the bending of the
shaft. This can be prevented by using two blocks on the two sides
of the drum as shown in fig (6). The braking torque becomes two
times. The braking torque is given by
TB  RN1  r  RN 2  r  RN1  RN 2   r
The value of (RN1) is obtained by taking moments of the forces
(RN1), (μRN1) and (P) about (O1). Similarly the value of (RN2) is
obtained by taking moments of the forces (RN2), (μRN2) and (P)
about (O2).

(2) Band brake Fig (6)

(a) Simple band brake
It consists of one or more ropes, belts or
flexible steel band lined with friction material,
which embraces a part of the circumference of the
rotating drum as shown in fig (7).
The braking force is provided by the friction
between the band and the drum. The force (P) at the
end of the lever for clockwise and anticlockwise
rotation of drum is obtained as explained below:
Let θ = Angle of lap of the band on the drum, Fig (7)
T1 = Tension in the tight side if the band,

3
T2 = Tension in the slack side if the band,
r = radius of the drum,
μ = Coefficient of friction between band and the drum,
t = Thickness of band,
 t
re = Effective radius of the drum =  r   , and
 2
L = OB = Length of the lever
P = Force at the end of the lever.
T
Limiting ratio of tension is given by  1  e  ......(9)
T2
Braking torque on the drum is given by
TB = (T1 – T2) * r (if thickness of belt is neglected)
TB = (T1 – T2) * re (if thickness of belt is considered)
To find the value of (P) for clockwise rotation drum shown in fig (7), the end of the band connected to
point (O) will be the slack side with tension (T2) and the end of the band attached to (A) will be tight
side with tension (T1). Taking moment about (O), we get  P  L  T1  a .......(10)
To find the value of (P) for anticlockwise rotation
drum shown in fig (8), the end of the band
connected to point (O) will be the tight side with
tension (T1) and the end of the band attached to (A)
will be slack side with tension (T2). Taking moment
about (O), we get  P  L  T2  a ......(11)
Where a = Perpendicular distance from (O) to the
Fig (8)
line of action of (T2).

Note: For simple band brake, one end of band is

always connected to the fulcrum (O).

(b) Differential band brake

In this case no end of the band is connected to the fixed point (O).
When the drum rotates in the clockwise
direction as shown in fig (9), the end of the
band attached at (A) will be tight with
tension (T1) whereas the end of the band
attached at (B) will be slack with tension
(T2) as shown in fig (9a). The value of force (a)
(P) can be obtained as explained below:
Let a = Perpendicular distance from (O) to the
line of action of (T2),
b = Perpendicular distance from (O) to the line
of action of (T1) and
L = length of lever from (O).
Consider the equilibrium of lever (BOC). The
force acting on the lever (BOC) are force (P), (b) Equilibrium of lever BOC
tension (T1) at (A) and tension (T2) at (B) as Fig (9)
shown in fig (9b). Taking moments of all
forces about (O), we get
4
 T2  a  T1  b
P  L  T1  b  T2  a  P ........(12)
L
But (T1) is always more than (T2). Hence the force (P) in equation (12) will be positive if
T1 a
T2  a  T1  b  T1  b  T2  a  
T2 b
In equation (12), the force will be zero or negative if
T2 b
T2  a  T1  b  
T1 a
If (P) is zero or negative, then the brake becomes as self locking.
When the drum rotates in the anticlockwise direction as shown in fig (10), the end of the band
connected to (B) will be tight with (T1) whereas the end of the band connecting to (A) will be slack
with (T2).
Taking moments about (O), we get
T  a  T2  b
P  L  T2  b  T1  a  P  1
L
For self locking of the brake, the force (P) should be zero
or negative. But force (P) will be zero or negative if
T1 b Fig (10)
T1  a  T2  b  
T2 a

(3) Band and block brake

This brake is a modification of the band
brake and consists of a number of wooden
blocks fixed inside a flexible steel band.
The friction between the blocks and the
drum provides braking action.
Let there are (n) number of blocks, each
subtending on an angle (2θ) at the drum
center as shown in fig (11).
For clockwise rotation, the end of band
attached to (A) will be tight with tension
(Tn) whereas the end attached to (B) will
be slack with tension (T0).
Let n = Number of blocks, (a) (b)
Tn = Tension on tight side after (n) block,
T0 = Tension on slack side, Fig (11)
T1 = Tension in the band between first and second block,
T2 = Tension in the band between second and third block.
Consider one of the blocks (say first block) as shown in fig (11b). This block is in equilibrium under the
action of (T0), (T1), (RN) and friction force (μRN).
The friction force on the drum will be in the opposite direction of the rotation of the drum, and the
frictional force on the block will be in the opposite direction of the frictional force on drum. Hence the
friction force on the block will be in clockwise direction.
Resolving the forces (fig (11b)) tangentially
T1 cos  T0 cos  RN  (T1  T0 ) cos  RN .......(i)
Resolving the forces radially
T1 sin   T0 sin   RN  (T1  T0 ) sin   RN .......(ii )
5
Dividing equation (i) by equation (ii) we get
T1  T0  T 1   tan 
  tan   1 
T1  T0  T0 1   tan 
T2 1   tan 
Similarly, for the second block the ratio of tension will be given by  and so on.
T1 1   tan 
Tn 1   tan 
For the (nth) block, the ratio of tension will be 
Tn 1 1   tan 
Hence the ratio of tensions in the tight and slack sides of the complete band and block brake can be
obtained as:
Tn T T T T  1   tan    1   tan    1   tan    1   tan  
 n  .......  3  2  1     .....         
T0 Tn 1 T2 T1 T0  1   tan    1   tan    1   tan    1   tan  
n
T  1   tan  
 n    .......(13)
T0  1   tan  
Now the braking torque on the drum will be TB  Tn - T0  re .......(14)
Where re = Effective radius of band.

The braking of a vehicle

The brakes in a car may be applied:

(1) To the rear wheels only, (2) to the front wheels only and (3) to all the four wheels.

(1) Value of retardation when the brakes are applied to rear wheels only
Let
W = Weight of the car = mg,
m = Mass of the car,
x = Perpendicular distance of C.G. of the car
from the rear axle,
h = Height of C.G. of car from road surface,
L = Wheel base of the car (distance between
the centers of the rear and front wheels),
RA = Reaction between front wheel and
ground,
RB = Reaction between rear wheel and
ground, Fig (12)
α = Angle of inclination of the plane with the horizontal,
μ = Coefficient of friction between the tires and
the road surface,
a = Retardation of vehicle.

Fig (12) shows the various forces acting on the car in which (FB) are the total braking force and is equal
to
FB    RB
Resolving the forces parallel to the inclined plane,

FB  mg sin   m  a  RB  mg sin   m  a ......(i )

6
Resolving the forces perpendicular to the inclined plane,

R A  RB  mg cos  ......(ii )

In equation (i) and (ii) there are three unknown (RA), (RB) and (a). Taking moments about (G), we get

FB  h  RB  x  R A (L  x) ......(iii )

From equations (i), (ii), and (iii) we get

RB 
L  x mg cos  RA 
mg cos  h  x  a
L  x g cos   g sin 
h  L  h  L  h  L 
Notes
(1) If the car is moving on a horizontal road, then (   0 ) and all the equations will be modified.
(2) If the car is moving down an inclined plane, then (FA) and (FB) will be acting upwards.

Solved examples for brakes

Ex1/ The brake drum of a single block brake of diameter 300 mm is rotating at 400 rpm (clockwise) as
shown in figure below. The force required at the end of the lever to apply the brake is 600 N. If angle of
contact is 90  and coefficient of friction between the drum and brake block is 0.3, find the braking
torque.

 4 sin  
Sol.  2  40 then      
 2  sin 2 
 
 4  sin 45 
    0.3   0.33
 90    sin 90 
 180 
Taking moments of all forces about O, we get
RN  250     RN  40  600  550  RN  1393.5 N
TB = Frictional force * radius of drum
 
TB     RN  r  0.33  1393.5  0.15  68.98 Nm

7
Ex2/ Figure below shows a simple band brake which is applied on a drum of diameter 400 mm. The
drum is rotating at 180 rpm. The angle of lap of the band on the drum is 270º and μ = 0.25. One end of
the band is attached to a fixed pin and other end to the lever arm at a distance of 100 mm from the
fulcrum. The lever length is 600 mm. The lever arm is placed perpendicular to the diameter that bisects
the angle of contact. Determine (i) the necessary force required at the end of the lever arm to stop the
drum if a power of 30 kW is being absorbed, (ii) width of steel band if maximum tensile stress in the
band is not to exceed 50 N/mm2. Take thickness of band as 3 mm.
Sol.
(i)
  
T 0.25 270 
 1  e   e  180   3.25
T2
T1  3.25  T2 ....(i )
Power  TB  
2    180
30  10 3  TB   TB  1591.55 Nm
60
TB  T1  T2   r  1591.55  T1  T2   0.2
 T1  T2   7957.75 ....(ii )
From equations (i) and (ii) we get (T1 = 11494.5 N) and (T2 = 3536.77 N)
Take moments of all forces about (O)
P  OB  T2  OC ....(iii ) where OC is the perpendicular dis tan ce from O to the line of action of T2

EFC  360  270  45 ,  FCE  45

OA 100 1
OD    50 mm ,
2 2 2
OD 50
In OCD, DCO  45 ,  cos 45   OC   70.71 mm
OC cos 45
Substituting the value of OC, OB and T2 in equation (iii)
P  600  3536.77  70.71  P  416.8 N
(ii) Maximum tension = Maximum tensile stress * Area of cross section of band
T1  f  b  t  11494.5  50  b  3  b  76.63 mm

Ex3/ Find the maximum braking

torque when a band and block
having 12 blocks, each of which
subtends an angle of 18º at the
drum center, is applied to a rotating
drum of diameter 800 mm. The
blocks are 100 mm thick. The two
ends of the band are attached to the
pin on the opposite sides of the
brake fulcrum at a distance of 35
mm and 140 mm from the fulcrum.
μ = 0.3. A force of 150 N is
applied at a distance of 800 mm
from the fulcrum to apply the
brake.

8
Sol.
As distance OA is greater than distance OB, The force must act downwards at C. For maximum
braking torque, the brake should be arranged so that the tight side of the band is attached to B. this is
possible if drum rotates clockwise as shown in figure.
n
Tn  1   tan  
 
T0  1   tan  
 1  0.3 tan 9 
12

   3.13
 1  0.3 tan 9 
Taking moment of all forces
about (O)
P  800  Tn  35  T0  140
P  800  3.13  T0   35  T0  140  T0  3940.88 N
 Tn  3.13  3940.88  12335 N
 TB  Tn  T0   r
 12335  3940.88  0.5
TB  4197 Nm

Ex4/ A car moving on a rough inclined plane are having the following data:
Angle of inclination of the plane = 15º; wheel base of the car = 2 m; height of C.G. of the car above the
inclined plane = 1 m; perpendicular distance of C.G. from rear axle = 0.9 m; speed of the car = 54 km/h;
μ = 0.45. If the brakes are applied to all the four wheels, determine, (i) distance traveled by the car
before coming to rest and (ii) time taken in doing so if (a) the car is moving up the plane, and (b) the car
is moving down the plane.
Sol.
54  1000
u  15 m / s
60  60
(a) a  g   cos   sin   9.810.45  cos15  sin 15  8.224 m / s2  8.224 m / s2 (retardatio n)
Let S = Distance traveled by the car before coming to rest
 v 2  u 2  2  a  S  0 2  152  2   8.224  S  S  13.68 m
 v  u  at  0  15   8.224  t  t  1.824 sec
(b) The figure shows all the forces acting on the car. The three equations of equilibrium are:
Along the plane,
FA  FB  ma  mg sin 
R A  RB  ma  mg sin  ....(i)
Perpendicular to the plane, R A  RB  mg cos  ...(ii )
Substituting the value of ( R A  RB ) in equation (i),
we get the retardation  a  g  cos   sin  
 Re tardation a  9.810.45  cos15  sin 15  3.147 m / s 2
 accelerati on a  3.147 m / s 2
 v 2  u 2  2  a  S  0 2  152  2   3.147  S  S  35.75 m
 v  u  at  0  15   3.147  t  t  4.76 sec

9
 (Homework’s)
Q1/ A simple band brake are applied to a rotating drum of diameter 500 mm. The angle of lap of the
band on the drum is 270º. One end of the band is attached to a fulcrum pin of the lever and other
end is to a pin 100 mm from the fulcrum. If μ = 0.25 and a braking force of 90 N is applied at a
distance 600 mm from the fulcrum, find the braking torque when the drum rotates in the
(i) clockwise direction, and (ii) anticlockwise direction.

Q2/ A differential band brake of drum diameter 400 mm.

The two ends of the band are fixed to the points on the
opposite side of fulcrum of the lever at a distance of 50
mm and 160 mm from the fulcrum as shown in figure.
The brake is to sustain a torque of 300 Nm. If μ = 0.2,
the angle of contact is 210º and the length of lever
from the fulcrum is 600 mm. Determine (i) the force
required at the end of the lever for the clockwise and
anticlockwise rotation of the drum, (ii) value of OB for
the brake to be self locking for clockwise rotation.

Q3/ The maximum braking torque acting on a band and block brake
is 8950 Nm. The band is lined with 12 blocks each of which
subtends an angle of 15º at the center of the rotating drum. The
diameter of the drum is 850 mm and thickness of the blocks is
75 mm. Find the least force required at the end of the lever,
which is 500 mm long as shown in figure. Take μ = 0.4.

Q5/ A car moving along a level road are having the following data:
Wheel base of the car = 2.8 m; distance of C.G. from ground surface =600 mm; perpendicular
distance of C.G. from rear axle = 1.2 m; speed on level road = 50 km/h; μ = 0.6. Determine the
minimum distance in which the car may be stopped when brakes are applied to the (i) rear wheels
only, (ii) front wheels only and (iii) all the four wheels.

Q6/ A car moving on a rough inclined plane are having the following data:
Angle of inclination of the plane = 10º; wheel base of the car = 1.8 m; height of C.G. of the car
above the inclined plane = 0.9 m; perpendicular distance of C.G. from rear axle = 0.8 m;
speed of the car = 36 km/h; μ = 0.6. If the brakes are applied to all the four wheels, determine the
distance traveled by the car before coming to rest.

Q7/ A differential band brake has a force of 220 N applied at the end of a
lever as shown in Figure. The coefficient of friction between the band
and the drum is 0.4. The angle of lap is 180°. Find (a) the maximum
and minimum tension in the band, when a torque of 450 N-m is
applied to the drum which rotate clockwise; and (b) the maximum
torque that the brake may sustain for anticlockwise rotation of the
drum.

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Q8/ In a band and block brake, the band is lined with 14 blocks, each of which subtends an angle of 20°
at the drum centre. One end of the band is attached to the fulcrum of the brake lever and the other to a
pin 150 mm from the fulcrum. Find the force required at the end of the lever 1 meter long from the
fulcrum to give a torque of 4 kN-m. The diameter of the drum is 1 meter, thickness of the blocks is
50 mm and the coefficient of friction between the blocks and the drum is 0.25.

Q9/ braking system has its braking lever inclined at an angle

of 30° to the horizontal plane, as shown in Figure. The
diameter of the brake drum is 540 mm and rotates
clockwise; the angle of contact surface of the block is
50°. At the instant the lever is pressed on the brake drum
with a vertical force of 600 N. The coefficient of friction
between the brake shoe and the brake drum is 0.4.
Assume that the lever and brake shoe are perfectly rigid
and possess negligible weight. Find the braking torque.

Q10/ A single block brake, as shown in figure, 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. The other
dimensions are as follows: a = 200 mm, l = 400 mm and b =
100 mm. If the torque transmitted by the brake is 70 N-m, find
the force F required to operate the brake.

Q11/ Figure shows a brake shoe applied to a drum by a lever AB

which is pivoted at a fixed point A and rigidly fixed to the shoe.
The radius of the drum is 160 mm. The coefficient of friction at
the brake lining is 0.3. If the drum rotates clockwise, find the
braking torque due to the horizontal force of 600 N at B.

Q12/ The simple band brake shown in figure is applied to a drum of

diameter 240 mm. The drum is rotating at 300 rpm. The angle of
contact of the band on the drum is 210º and μ = 0.2. One end of the
band is attached to a fixed end A and other end to the lever arm at a
distance 120 mm from A. The lever length is 420 mm. Determine
(a) the braking torque and (b) width of steel band if the maximum
tensile stress in the band is not exceed 15 N/mm2. Take thickness of
band as 3 mm.
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Q13/ A single block brake is shown in figure. The diameter of the
drum is 250 mm and the angle of contact is 90°. If the
operating force of 700 N is applied at the end of a lever and
the coefficient of friction between the drum and the lining is
0.35, determine the torque that may be transmitted by the
block brake.

Q14/ A double shoe brake, as shown in figure, is capable of absorbing a torque

of 1400 N-m. The diameter of the brake drum is 350 mm and the angle of
contact for each shoe is 100°. If the coefficient of friction between the
brake drum and lining is 0.4, find the spring force (S) necessary to set the
brake if the drum rotate clockwise.

Q15/ Differential band brakes are shown in figure. 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
anticlockwise rotation of the drum: (a) the maximum and
minimum forces in the band; and (b) the torque which can be
applied by the brake. (Note: all dimensions in mm).

Q16/ A single block brake, as shown in Figure, 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 operating force of 650 N is applied at
the end of the lever, determine the torque that may be transmitted by the
block brake.

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