826 Budynas−Nisbett: Shigley’s III. Design of Mechanical 16.

Clutches, Brakes, © The McGraw−Hill

Mechanical Engineering Elements Couplings, and Flywheels Companies, 2008
Design, Eighth Edition

Clutches, Brakes, Couplings, and Flywheels 829

16–6 Disk Brakes

As indicated in Fig. 16–16, there is no fundamental difference between a disk clutch
and a disk brake. The analysis of the preceding section applies to disk brakes too.
We have seen that rim or drum brakes can be designed for self-energization. While
this feature is important in reducing the braking effort required, it also has a disadvantage.
When drum brakes are used as vehicle brakes, only a slight change in the coefficient of
friction will cause a large change in the pedal force required for braking. A not unusual 30
percent reduction in the coefficient of friction due to a temperature change or moisture, for
example, can result in a 50 percent change in the pedal force required to obtain the same
braking torque obtainable prior to the change. The disk brake has no self-energization, and
hence is not so susceptible to changes in the coefficient of friction.
Another type of disk brake is the floating caliper brake, shown in Fig. 16–18. The
caliper supports a single floating piston actuated by hydraulic pressure. The action is
much like that of a screw clamp, with the piston replacing the function of the screw. The
floating action also compensates for wear and ensures a fairly constant pressure over
the area of the friction pads. The seal and boot of Fig. 16–18 are designed to obtain
clearance by backing off from the piston when the piston is released.
Caliper brakes (named for the nature of the actuating linkage) and disk brakes
(named for the shape of the unlined surface) press friction material against the face(s)

Figure 16–18
Caliper
Wheel Boot Seal
An automotive disk brake.
(Courtesy DaimlerChrysler Piston
Corporation.)

Brake fluid

Shoe and
lining

Wheel stud Inner

bearing Seal

Spindle
Adapter

Mounting bolt

Outer
bearing Steering
knuckle

Braking disk
Splash shield
 Budynas−Nisbett: Shigley’s III. Design of Mechanical 16. Clutches, Brakes, © The McGraw−Hill 827
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Design, Eighth Edition

830 Mechanical Engineering Design

Figure 16–19 y

Geometry of contact area of

an annular-pad segment of a
caliper brake. F F

r
␪2
ro ri
x
␪1

of a rotating disk. Depicted in Fig. 16–19 is the geometry of an annular-pad brake con-
tact area. The governing axial wear equation is Eq. (12–27), p. 643,
w = f1 f2 K P V t
The coordinate r̄ locates the line of action of force F that intersects the y axis. Of
interest also is the effective radius re , which is the radius of an equivalent shoe of infin-
itesimal radial thickness. If p is the local contact pressure, the actuating force F and the
friction torque T are given by
 θ2  ro  ro
F= pr dr dθ = (θ2 − θ1 ) pr dr (16–29)
θ1 ri ri

 θ2  ro  ro
T = f pr 2 dr dθ = (θ2 − θ1 ) f pr 2 dr (16–30)
θ1 ri ri

The equivalent radius re can be found from f Fre = T , or

 ro
pr 2 dr
T r
re = =  i ro (16–31)
fF
pr dr
ri

The locating coordinate r̄ of the activating force is found by taking moments about the
x axis:
 θ2  ro  ro
Mx = F r̄ = pr(r sin θ) dr dθ = (cos θ1 − cos θ2 ) pr 2 dr
θ1 ri ri

Mx (cos θ1 − cos θ2 )
r̄ = = re (16–32)
F θ2 − θ1

Uniform Wear
It is clear from Eq. (12–27) that for the axial wear to be the same everywhere, the prod-
uct P V must be a constant. From Eq. (a), Sec. 16–5, the pressure p can be expressed
in terms of the largest allowable pressure pa (which occurs at the inner radius ri ) as
828 Budynas−Nisbett: Shigley’s III. Design of Mechanical 16. Clutches, Brakes, © The McGraw−Hill
Mechanical Engineering Elements Couplings, and Flywheels Companies, 2008
Design, Eighth Edition

Clutches, Brakes, Couplings, and Flywheels 831

p = pa ri /r . Equation (16–29) becomes

F = (θ2 − θ1 ) pa ri (ro − ri ) (16–33)

Equation (16–30) becomes

ro
1

(θ2 − θ1 ) f pa ri ro2 − ri2
 
T = (θ2 − θ1 ) f pa ri r dr = (16–34)
ri 2
Equation (16–31) becomes
 ro
pa ri r dr
ri ro2 − ri2 1 r o + ri
re =  ro = = (16–35)
2 r o − ri 2
pa ri dr
ri

Equation (16–32) becomes

cos θ1 − cos θ2 ro + ri
r̄ = (16–36)
θ2 − θ1 2

Uniform Pressure
In this situation, approximated by a new brake, p = pa . Equation (16–29) becomes
 ro
1
r dr = (θ2 − θ1 ) pa ro2 − ri2
 
F = (θ2 − θ1 ) pa (16–37)
ri 2
Equation (16–30) becomes
ro
1

r 2 dr = (θ2 − θ1 ) f pa ro3 − ri3
 
T = (θ2 − θ1 ) f pa (16–38)
ri 3
Equation (16–31) becomes
 ro
pa r 2 dr
r 3 − ri3 2 2 ro3 − ri3
re = ri ro = o = (16–39)
3 ro2 − ri2 3 ro2 − ri3
pa r dr
ri

Equation (16–32) becomes

cos θ1 − cos θ2 2 ro3 − ri3 2 ro3 − ri3 cos θ1 − cos θ2

r̄ = = (16–40)
θ2 − θ1 3 ro2 − ri2 3 ro2 − ri2 θ2 − θ1

EXAMPLE 16–3 Two annular pads, ri = 3.875 in, ro = 5.50 in, subtend an angle of 108◦ , have a co-
efficient of friction of 0.37, and are actuated by a pair of hydraulic cylinders 1.5 in in
diameter. The torque requirement is 13 000 lbf · in. For uniform wear
(a) Find the largest normal pressure pa .
(b) Estimate the actuating force F.
(c) Find the equivalent radius re and force location r̄ .
(d) Estimate the required hydraulic pressure.
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Design, Eighth Edition

832 Mechanical Engineering Design

Solution (a) From Eq. (16–34), with T = 13 000/2 = 6500 lbf · in for each pad,

2T
Answer pa =
(θ2 − θ1 ) f ri ro2 − ri2
 

2(6500)
= = 315.8 psi
(144◦ − 36◦ )(π/180)0.37(3.875)(5.52 − 3.8752 )

(b) From Eq. (16–33),

Answer F = (θ2 − θ1 ) pa ri (ro − ri ) = (144◦ − 36◦ )(π/180)315.8(3.875)(5.5 − 3.875)

= 3748 lbf

(c) From Eq. (16–35),

r o + ri 5.50 + 3.875
Answer re = = = 4.688 in
2 2

From Eq. (16–36),

Answer cos θ1 − cos θ2 ro + ri cos 36◦ − cos 144◦ 5.50 + 3.875

r̄ = =
θ2 − θ1 2 (144◦ − 36◦ )(π/180) 2
= 4.024 in

(d) Each cylinder supplies the actuating force, 3748 lbf.

F 3748
Answer phydraulic = = = 2121 psi
AP π(1.52 /4)

R Circular (Button or Puck) Pad Caliper Brake

Figure 16–20 displays the pad geometry. Numerical integration is necessary to ana-
lyze this brake since the boundaries are difficult to handle in closed form. Table 16–1
e gives the parameters for this brake as determined by Fazekas. The effective radius is
given by

re = δe (16–41)

The actuating force is given by

F = π R 2 pav (16–42)
Figure 16–20
and the torque is given by
Geometry of circular pad of a
caliper brake. T = f Fre (16–43)
830 Budynas−Nisbett: Shigley’s III. Design of Mechanical 16. Clutches, Brakes, © The McGraw−Hill
Mechanical Engineering Elements Couplings, and Flywheels Companies, 2008
Design, Eighth Edition

Clutches, Brakes, Couplings, and Flywheels 833

Table 16–1 R re pmax

␦ⴝ
e e pav
Parameters for a
Circular-Pad Caliper 0.0 1.000 1.000
Brake 0.1 0.983 1.093
Source: G. A. Fazekas, “On 0.2 0.969 1.212
Circular Spot Brakes,” Trans. 0.3 0.957 1.367
ASME, J. Engineering for
Industry, vol. 94, Series B, 0.4 0.947 1.578
No. 3, August 1972, 0.5 0.938 1.875
pp. 859–863.

EXAMPLE 16–4 A button-pad disk brake uses dry sintered metal pads. The pad radius is 12 in, and its
center is 2 in from the axis of rotation of the 3 12 -in-diameter disk. Using half of the
largest allowable pressure, pmax = 350 psi, find the actuating force and the brake
torque. The coefficient of friction is 0.31.

Solution Since the pad radius R = 0.5 in and eccentricity e = 2 in,

R 0.5
= = 0.25
e 2
From Table 16–1, by interpolation, δ = 0.963 and pmax / pav = 1.290. It follows that the
effective radius e is found from Eq. (16–41):
re = δe = 0.963(2) = 1.926 in
and the average pressure is
pmax /2 350/2
pav = = = 135.7 psi
1.290 1.290
The actuating force F is found from Eq. (16–42) to be

Answer F = π R 2 pav = π(0.5)2 135.7 = 106.6 lbf (one side)

The brake torque T is

Answer T = f Fre = 0.31(106.6)1.926 = 63.65 lbf · in (one side)

16–7 Cone Clutches and Brakes

The drawing of a cone clutch in Fig. 16–21 shows that it consists of a cup keyed or splined
to one of the shafts, a cone that must slide axially on splines or keys on the mating shaft,
and a helical spring to hold the clutch in engagement. The clutch is disengaged by means
of a fork that fits into the shifting groove on the friction cone. The cone angle α and the
diameter and face width of the cone are the important geometric design parameters. If the