Chapter 18: Brakes and Clutches

Nothing has such power to broaden

the mind as the ability to investigate
systematically and truly all that
comes under thy observation in life.

Marcus Aurelius,
Roman Emperor

A truck brake drum with cooling fins

around the periphery for extended life and
improved performance. Source: Courtesy of
Webb Wheel Products, Inc.

Fundamentals of Machine Elements, 3rd ed.

2014 CRC Press
Schmid, Hamrock and Jacobson
 Brakes and Clutches

Figure 18.1: Five types of brake and clutch. (a) Internal, expanding rim type; (b) external
contracting rim type; (c) band brake; (d) thrust disk; (e) cone disk.

Fundamentals of Machine Elements, 3rd ed.

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Schmid, Hamrock and Jacobson
Applications of Clutches and Brakes

Table 18.1: Typical applications of clutches and brakes.

Fundamentals of Machine Elements, 3rd ed.

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Schmid, Hamrock and Jacobson
 Thermal Considerations

Figure 18.2: Brake rotor surface Figure 18.3: Hard spot on a brake
showing a high level of heat checking. drum. Source: Courtesy Webb Wheel
Source: Courtesy Webb Wheel Products, Products, Inc.
Inc.

Fundamentals of Machine Elements, 3rd ed.

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Schmid, Hamrock and Jacobson
Limiting Pressure-Velocity Product

Table 18.2: Product of contact pressure and sliding velocity for brakes and clutches.
Source: Juvinall, R.C., and Marshek, K.M. [2006].

Fundamentals of Machine Elements, 3rd ed.

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Schmid, Hamrock and Jacobson
 Disk Brakes

Figure 18.4: Thrust brake terminology and operation. (a) Illustration of a thrust brake,
with wheel removed for clarity. Note that the caliper shown has a window to allow
observation of the brake pad thickness, a feature that is not always present. (b) Section
view of the disk brake, showing the caliper and brake cylinder.

Fundamentals of Machine Elements, 3rd ed.

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Schmid, Hamrock and Jacobson
Disk Clutch and Radius Ratio

Figure 18.5: Thrust disk clutch Figure 18.6: Effect of radius ratio
surface with various radii. on dimensionless torque for
uniform pressure and uniform
wear models.

Fundamentals of Machine Elements, 3rd ed.

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Schmid, Hamrock and Jacobson
 Brake Material Properties
Maximum contact Maximumbulk
Coeffic
i en t of pressure,a pmax temperature, tm, max
Friction material friction, psi kPa F C
Molded 0.25-0.45 150-300 1030-2070 400-500 204-260
Woven 0.25-0.45 50-100 345-690 400-500 204-260
Sintered metal 0.15-0.45 150-300 1030-2070 400-1250 204-677
Cork 0.30-0.50 8-14 55-95 180 82
Wood 0.20-0.30 50-90 345-620 200 93
Cast iron; hard steel 0.15-0.25 100-250 690-1720 500 260
a Use of lower values will give longer life.

Table 18.3: Representative properties of contacting materials operating dry, when

rubbing against smooth cast iron or steel.

Fundamentals of Machine Elements, 3rd ed.

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Schmid, Hamrock and Jacobson
 Friction Coefficient

Friction material Coeffic

i en t of friction,
M ol d e d 0.06-0.09
Woven 0.08-0.10
Sintered metal 0.05-0.08
Paper 0.10-0.14
Graphitic 0.12 (avg.)
Polymeric 0.11 (avg.)
C or k 0.15-0.25
Wood 0.12-0.16
Cast iron; hard steel 0.03-0.16

Table 18.4: Coefficient of friction for contacting materials operating in oil when rubbing
against steel or cast iron.

Fundamentals of Machine Elements, 3rd ed.

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Schmid, Hamrock and Jacobson
 Cone Clutch

Figure 18.7: Forces acting on elements of cone clutch.

Fundamentals of Machine Elements, 3rd ed.

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 Block Brake

Figure 18.8: Block, or short-shoe brake, with two configurations.

Fundamentals of Machine Elements, 3rd ed.

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Schmid, Hamrock and Jacobson
 Example 18.3

Figure 18.9: Short-shoe brake used in Example 18.3.

Fundamentals of Machine Elements, 3rd ed.

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Schmid, Hamrock and Jacobson
 Drum Brake

Figure 18.10: A typical automotive long-shoe, internal, expanding rim brake, commonly
called a drum brake.

Fundamentals of Machine Elements, 3rd ed.

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Schmid, Hamrock and Jacobson
 Long Shoe Brake

Figure 18.11: Long-shoe, internal, Figure 18.12: Forces and dimensions of

expanding rim brake with two shoes. long-shoe, internal expanding rim
brake.

Fundamentals of Machine Elements, 3rd ed.

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Schmid, Hamrock and Jacobson
 Design Procedure 18.1: Long-Shoe,
Internal, Expanding Brake Analysis
This Design Procedure outlines the method used to obtain the maximum allowable
brake force (which can be controlled by design of the hydraulic or pneumatic
actuators) and braking torque.

1. Select a brake material. A reasonable starting point is to assume the drum is made
of steel, using sintered metal lining material. Table 18.2 then allows estimation of
maximum allowable contact pressure and friction coefficient. Table 18.3 also
recommends a maximum pressure, but based on thermal conditions. The lower of
the two contact pressures should be used for further analysis.
2. Draw a free body diagram of the brake shoes, paying special attention to the force
that acts on the shoes due to friction. Identify which of the shoes, if any, are self-
energizing or deenergizing. In a self-energizing shoe, the moment due to frictional
force applied to the shoe will have the same sign as the moment due to the
applied force. If it is not clear that a shoe is self-energizing or deenergizing, then
assume the brake is self-energizing in order to be conservative regarding
maximum shoe pressure. In any case, if the friction moment is close to zero, then
the braking torque will be similar whether the brake was assumed to be self-
energizing or deenergizing.

Fundamentals of Machine Elements, 3rd ed.

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Schmid, Hamrock and Jacobson
 Design Procedure 18.1 (continued)
3. Evaluate MP and MF from Eqs. (18.40) and (18.41), respectively. Note that
one or more terms may be unknown, but they can be treated as variables.
4. Consider the self-energizing shoe first. The self-energizing shoe will
encounter a higher pressure than the deenergizing shoe, so that the
limiting pressure determined above can be used to evaluate MP and MF.
5. Equation (18.43) can be used to determine the maximum braking force.
Note that a lower braking force can be applied, but a higher braking force
would exceed the allowable stress of the lining material, leading to plastic
deformation or compromised brake life. If the braking force was
prescribed, then Eq. (18.43) can be used to obtain the pressure in the shoe,
which can be compared to the maximum allowable pressure obtained
previously.
6. Equation (18.44) can be used to obtain the torque for the self-energizing
shoe.

Fundamentals of Machine Elements, 3rd ed.

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Schmid, Hamrock and Jacobson
 Design Procedure 18.1 (concluded)
7. Equations (18.46) and (18.48) can be used to obtain the hinge pin reaction
forces.
8. In most brakes, the force applied to the self-energizing and deenergizing
shoes are the same. However, the maximum pressure on the deenergizing
shoe will be lower than the self-energizing one. Thus, the applied force and
pressure can be taken from the self-energizing shoe analysis, as this will
reflect the higher stress.
9. Equation (18.50) allows calculation of the maximum pressure on the
deenergizing shoe.
10. The torque can be obtained from Eq. (18.45) using the maximum pressure for
the deenergizing shoe.
11. Equations (18.51) and (18.52) allow calculation of the hinge pin reaction
forces.

Fundamentals of Machine Elements, 3rd ed.

2014 CRC Press
Schmid, Hamrock and Jacobson
 Example 18.4

Figure 18.13: Four-long-shoe, internal expanding rim brake used in Example 18.4.

Fundamentals of Machine Elements, 3rd ed.

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Schmid, Hamrock and Jacobson
 Long-Shoe External Brake

Figure 18.14: Forces and dimensions of long-shoe, external, contracting rim brake.

Fundamentals of Machine Elements, 3rd ed.

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 Pivot-Shoe Brake

Figure 18.15: Symmetrically loaded pivot-shoe brake.

Fundamentals of Machine Elements, 3rd ed.

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 Band Brake Forces

Figure 18.17: Band brake. (a) Forces acting on band; (b) forces acting on element.

Fundamentals of Machine Elements, 3rd ed.

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Schmid, Hamrock and Jacobson
 Example 18.7

Figure 18.18: Band brake used in Example 18.7.

Fundamentals of Machine Elements, 3rd ed.

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Schmid, Hamrock and Jacobson
Case Study: Roller Coaster Brake System

Figure 18.20: Schematic illustration of a roller

coaster brake system. (a) Components of the
roller coaster and shown when the brake is
Figure 18.19: A typical roller not engaged, as seen by the gap between the
coaster. liner pads; (b) Top view of an engaged brake;
(c) side view of engaged brake.
Fundamentals of Machine Elements, 3rd ed.
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Schmid, Hamrock and Jacobson
 Roller Coaster Cars

Figure 18.21: Schematic illustration of typical roller coaster cars.

Fundamentals of Machine Elements, 3rd ed.

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Schmid, Hamrock and Jacobson
 Brake Detail

Figure 18.22: Detail of brake- Figure 18.23: Cross-section of the

actuating cylinder with forces shown. actuating pneumatic cylinder,
highlighting the helical springs
incorporated into the design.

Fundamentals of Machine Elements, 3rd ed.

2014 CRC Press
Schmid, Hamrock and Jacobson