Brakes

1. Energy equations
i) Kinetic Energy :

m ( v12 v22 )
1
K .E =
2
where K .E = Kinetic Energy ( J )
m = mass of the system(kg )
v1 , v2 = Initial and Final velocities (m / sec)

m ( v12 v22 ) f the Rotating Body

1
Kinetic Enrgy oK .E =
2
I (12 22 )
1
K .E =
2
I = mk 2
where I = Mass moment of Inertia of rotating body (kg m 2 )
k = Radius of gyration(m)

ii) Potential Energy :

P.E = m.g.h
Where h = height
iii) Energy absorbed by the brake :
E = M t .
Where E = Energy absorbed by brake (in J )
( K .E or P.E or Both )
M t = Braking Torque
= Angle through which the brake drum
during breaking period (in radian)

2. Block brake with short shoe :

i) Breaking Torque
M t = . N .R
where M t = Breaking Torque( N mm)
R = Radius of the brake drum(mm)
= Co efficient of friction
N = Normal Re action( N )

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 N = p.l.w
where p = permissible pressure between the block
and the brake drum( N / mm 2 )
l = length of block (mm)
w = width of block (mm)

P=
( a c ) N
b
Where P = Actuating Force
a, c = distace of the shoe from pivot
b = distace of Actuating force from pivot
Case i : a > c Not self locking
Case ii : a = c Self locking
Case iii : a < c Uncontrolled bracking

3. Pivot block Brake with long Shoe :

i) Distance of the Pivot from the center of the brake drum (h)
4 R Sin
h=
2 + Sin2
Where R = Radius of the brake drum
2 = Included angle of the friction lining

ii) Breaking Torque (Mt)

M t = 2 R 2 w pmax Sin
Where = co efficient of friction
R = radius of the drum
w = width of the drum
pmax = Maximum pressure between the drum
and linining

iii) Reactions at the Pivot

1
Rx = R w pmax [ 2 + Sin2 ]
2

2
 1
Ry = R w pmax [ 2 + Sin2 ]
2

iv) Equivalent Co-efficient of friction( ' )

4 Sin
'=
2 + Sin 2
M t = '.N .R
where M t = Breaking Torque( N mm)
R = Radius of the brake drum(mm)
' = Eqivalent co efficient of friction
N = Normal Re action( N )

4. Internal Expanding Shoe Brake :

i) Breaking torque (Mt)

R 2 pmax w ( Cos1 Cos 2 )

Mt =
Sinmax

ii) Friction Torque (Mf)

pmax R w 4 R ( Cos1 Cos 2 ) h ( Cos 21 Cos 2 2 )
Mf =
4 Sinmax

iii) Normal Torque (Mn)

pmax R w h 2 ( 2 1 ) ( Sin 2 2 Sin21 )
Mn =
4 Sinmax

iv) For clock wise rotation of brake drum, Actuating force(P)

Mn M f
P=
C
v) For Counter clock wise rotation of brake drum, Actuating force(P)
Mn + M f
P=
C

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vi) Thermal considerations
E
t =
m.c
Where t = Temperature rise of the brake drum Assembly (C )
E = Total Energy abosorbed by the brake( J )
m = Mass of the Brake drum assembly (kg )
c = Specific heat of the brake drum material ( J / kg C )

Rolling Contact Bearings

1. Stribocks Equation

k d2 z
Co =
5
Where C0=Static load
K=factor depends on the radii of curvature at the point of contact, and on the
modulus of Elasticity of material.

2. Equivalent bearing load (P)

P=XFr + YFa
Where Fr=Radial load(N)
Fa=Axial or Thrust load(N)
X,Y are radial and thrust factors respectively
3. Moment of Friction force(Mt) = N R
Where N=Fr
R=Radius of the bearing
=Co-efficient of friction
4. Load life Relationship
p
C
L=
P
Where L=Bearing life (in million revolutions)
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 C=Dynamic load capacity (N)
P=Equivalent bearing load (N)
p=3 (for ball bearings)
p=10/3 (for Roller bearings)

5. Relation between life in million revolutions and life in working hours is given by

60 n Lh
L=
106
Where Lh=Bearing life (Hours)
n=Speed of rotation (r.p.m)

6. Taper Roller bearings Refer Table 15.4 in V.B.Bandari

7. Design for Cyclic loads and Speeds

N1 P13 + N 2 P23 + . . .
Pe = 3
N1 + N 2 + . . .

Where P1,P2 . . . are loads and N1,N2 . . . are speed for the respective elements
8. Reliability (R)=
No.of bearings which have successfully completed L Million revolutions
R=
Total no. of bearings under test

( a)
b
L
R=e Wiebulls equation
Where L=Corresponding life
a,b are constants
1
1
b

log e
L
= R
L90 1 where a=6.84 and b=1.17
log e
90
R

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 Sliding Contact Bearings
1. Newtons Law of Viscosity : According to Newtons law of viscosity, the shear stress
is proportional to the ratio of shear at any point in the fluid.

P
=
A
N s
2. Units of Dynamic or Absolute viscosity ( ) are
mm 2
Dyne s
Popular Unit for viscosity are Poise = is denoted with z
cm 2
3. Relation between z and

z
=
109
4. Kinematic visocity(Zk)

180
zk = 0.22 t +
t
Where t = Viscosity in SAYBOLT Universal Seconds (SUS)
Zk in Centi Stokes(cSt)
5.
z
zk =

Where = density of Lubricant gm / cm3
6. Hydrostatic Step Bearing

Pi ho3
Q=
R
6 log e 0
Ri

Pi R02 Ri2
W=
2 R
log e 0
Ri
Where W=Thrust load(N)
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R0 = Outer radius of the shaft(mm)
Ri = Inner radius of the shaft (mm)
Pi=Supply of inlet pressure(N/mm2)
Po=Outlet or atmospheric pressure (N/mm2)
h=fluid film thickness (mm)
Q=Flow of lubricant (mm3/sec)
=Viscosity of the lubricant (N-s/mm2)

7. Power losses (KW)t= (KW)p+(KW)f

(KW)t= Total power loss
(KW)p = Power loss in pumping
(KW)f = Power loss due to friction

(KW)p= Q( Pi Po ) 106

n ( Ro Ri )
2 4 4
1
(KW)f =
58.05 10
6
ho

8. Hydrostatic conical thrust bearing

Pi ho3 Sin
Q=
R
6 log e 0
Ri

2
Pi R0 Ri2
W=
2 R
log e 0
Ri

9. Raimondi and Boyd Method

e
=
c
where e = eccentricity
c = Radial clearance

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 ho
= 1
c
Where h0= minimum film thickness
ho
=minimum film thickness variable
c

10. Sommerfeld Number(S)

r ns
2

S =
c p
where S = Sommerfeld number( Dimension less)
= visocity of thelubricant ( N s / mm2 )
ns = Journal speed ( rev / sec )
p = Unit bearing pressure, Load per unit projected area ( N / mm 2 )
________________________________________
2
ZN d
Sommerfeld Number ( S ) =
p c
For design purpose its value is taken as
2
ZN d
= 14.3 10 (When Z is in kg / m.s and p is in N / mm
6 2

p c
2
ZN d
= 14.3 10 (When Z is in CentiPoise and p is in kgf / cm
9 2

p c

11. Co- efficient of friction variable(C.F.V)

r
C.F .V = . f
c
where r = Radius of journal
c = Radial clearance
f = co efficient of friction

12. Frictional Torque(Mt) = f.W.r in N-mm

13. Friction Power
2 . f .W .r
( K .W ) f = in KW
106

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14. Flow variable (F.V)
Q
( F .V ) =
r.c.ns .l
where Q = flowof the lub ricant (mm3 / sec)
l = length of the bearing (mm)
15. Mc Kees Equation

33 Z N r
f = + K
108 p c
Where f= co-efficient of friction
Z=absolute viscosity in kg/m-sec
1 centi poise = 0.01 poise
1 centi poise =0.001 kg/m.s
p=bearing pressure on the projected area in N/mm2
c=radial clearance (R-r)
K=factor to correct for end leakages. It depends on l/d ratio
K=0.02 for l/d of 0.78 to 2.8
N=Speed of the journal in r.p.m

16. Temperature rise

8.3 p (C.F .V )
t =
( F .V )

Wire Ropes

1. Bending stress ( b )

Er d w
b =
D
Er = effective mod ulus of elasticity
d w = Wire diameter of individual wire (mm)
D = Diameter of sheave (mm)

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2. Equivalent bending Load (Pb)
AEr d w
Pb =
D
A = Area of the metallic cross sec tion of the wire rope
Er = effective mod ulus of elasticity
d w = Wire diameter of individual wire (mm)
D = Diameter of sheave (mm)
3. Pressure between the rope and the sheave(p)
2P
p=
dr D
P = Tension in the rope( N )
d r = No min al dia of the wire rope (mm)
D = Diameter of sheave (mm)

Chain Drives
1. Pitch angle( )
360
= where z=No.of teeth on the sprocket
z
2. Pitch diameter of the Sprocker(D)
p
D= where p=pitch of the sprocket or chain
180
sin
z
z2 n1
3. Velocity ratio (i)= =
z1 n2
Where z1 = number of teeth on driving sprockets
z2= number of teeth on driven sprockets
n1 = speed of driving sprockets
n2= speed of driven sprockets
4. Length of the chain L = Ln P
Where Ln= No.of links in chain
L=Length of the chain in mm

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5.
a z +z z z p
2

Ln = 2 + 1 2 + 2 1
p 2 2 a
Where a = centre between between the sprockets ( mm )
z1 = No.of teeth on the smaller sprocket
z2 = N .of teeth on the l arg er sprocket
6. Polygonal effect
180
(vmax vmin ) 1 cos
z
7. Power transmitted by the chain (KW)
Pv
KW = 1
1000
where P1 = allowable tension in the chain ( N )
v = average velocity of chain (m / s )
8. Power rating of the chain
( KW to be transmitted ) K s
KW rating =
K1 K 2
where K s = Service factor
K1 = multiple strand factor
K 2 = tooth correction factor

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