International Journal of Science and Research (IJSR)

ISSN: 2319-7064
ResearchGate Impact Factor (2018): 0.28 | SJIF (2018): 7.426

Design and Manufacturing of Brake Shoe

Praveen Pachauri1, Arshad Ali2
1
ME Prof., Mechanical Department, Noida Institute of Engineering & Technology, Gr. Noida, India
2
UG, Mechanical Engineering, Noida Institute of Engineering & Technology, Gr. Noida, India

Abstract: The aim of this article is to design and manufacturing of Hero Honda Splendor brake shoe. Analysis is done by changing the
material of the brake shoe, under different braking time and operational conditions. Brake shoe is optimized to obtain different stresses,
deformation values on different braking time. Optimized results obtained are compared for Aluminium alloy and Gray cast iron
material. It concludes that the aluminium alloys can be a better candidate material for the brake shoe applications of light commercial
vehicles and it also increases the braking performance.

Keywords: Brake shoe, Al alloy brake shoe, Grey cast iron brake shoe, Finite Element Analysis, and Solid works

1. Introduction when brakes are not applied. The brake drum Braking
System closes inside it the whole mechanism to protect it
Drum brakes were the first types of brakes used on motor from dust and first. A plate holds whole assembly and fits to
vehicles. Nowadays, over 100 years after the first usage, car axle. It acts as a base to fasten the brake shoes and other
drum brakes are still used on the rear wheels of most operating mechanism. Braking power is obtained when the
vehicles. The drum brake is used widely as the rear brake brake shoes are pushed against the inner surface of the drum
particularly for small car and motorcycle. The leading- which rotates together with the axle. Drum brakes are
trailing shoe design is used extensively as rear brake on mainly used for the rear wheels of passenger cars and trucks
passenger cars and light weight pickup trucks. Most of the while disc brakes are used exclusively for front brakes
front-wheel-drive vehicles use rear leading- trailing shoe because of their greater direction stability. The backing plate
brakes. Such design provided low sensitivity to lining is a pressed steel plate, bolted to the rear axle housing. Since
friction changes and has stable torque production (Limpert, the brake shoes are fitted to the backing plate, all of the
1999).[1] A brake is a mechanical device which is used to braking force acts on the backing plate. A drum brake has a
absorb the energy possessed by a moving system or hollow drum that turns with the wheel. Its open back is
mechanism by means of friction. The primary purpose of the covered by a stationary back plate on which there are two
brake is to slow down or completely stop the motion of a curved shoes carrying friction linings. The shoes are forced
moving system, such as a rotating disc/drum, machine or outwards byhydraulic pressure moving pistons in the brake’s
vehicle. Many aspects of slowing and stopping a vehicle are wheel cylinders, so pressing the linings against the inside of
controlled by simple physics dealing with the deceleration of the drum to slow or stop it.[4] Optimal design of today's
a body in motion. The simplest way to stop a vehicle is to brake systems is found using additional calculations based
convert the kinetic energy into heat energy. The energy on Finite element methods. For both types of brake systems,
absorbed by brakes is dissipated in the form of heat. The drum brakes and disk brakes. Results include deformation,
heat is dissipated in surrounding, air, water etc. [2] The stress distribution, contact pressure and showing which
braking equipment of a vehicle includes all of its brake regions of the contact area are in sticking or sliding
system that is all of reducing velocity of a moving vehicle, condition. [5] A parametric modeling of a drum shoe based
reducing its rate of acceleration, increasing its rate of on 3-D Finite Element Methods for non-contact analysis is
deceleration, halting the acceleration, increasing its rate of presented. Many parameters are examined during this study
deceleration, halting the vehicle and preventing the vehicle such as the effect of shoe-lining interface stiffness,
from returning movement once it is stationary. [3] A drum coefficient of friction, and line pressure on the interface
brake is a brake that uses friction caused by a set of shoes or contact. It is shown that the Unsymmetrical modal analysis
pads that press against a rotating drum shaped part called a is efficient enough to solve this linear problem after
brake drum. The brake drum is generally made of cast iron transforming the non-linear behavior of the contact between
that rotates with the wheel. When a driver applies the brakes, the drum and the lining to a linear behavior. [6] A multi
the lining pushes radially against the inner surface of the objective optimization design model of drum brake with the
drum, and the ensuing friction slows or stops rotation of the goals of maximizing the efficiency factor of braking, and
wheel and axle, and thus the vehicle. Internal expanding minimizing the volume of drum brake, in order to better
shoe brakes are most commonly used in automobiles. In an meet the requirements of engineering practice.
automobile, the wheel is fitted on a wheel drum. The brake
shoes come in contact with inner surface of this drum to 2. Literature Review
apply brakes. The whole assembly consists of a pair of brake
shoes along with brake linings, a retractor spring two anchor K. Radhakrishna et al (2008) - He had used aluminium
pins a cam and a brake drum. Brake linings are fitted on with copper and fly ash as reinforcements and concluded
outer surface of each brake shoe. The brake shoes are hinged that up to 15% the reinforcements are successfully dispersed
at one end by anchor pins. Other end of brake shoe is in the matrix and hardness, wear resistance increases up to
operated by a cam to expand it out against brake drum. A 15 wt% addition of reinforcements.[7]
retracting spring brings back shoes in their original position

Volume 8 Issue 8, August 2019

www.ijsr.net
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Paper ID: ART2020286 10.21275/ART2020286 580
 International Journal of Science and Research (IJSR)
ISSN: 2319-7064
ResearchGate Impact Factor (2018): 0.28 | SJIF (2018): 7.426
K. Deepika et al (2013) - Brake lining materials generally Solid Modeling: The first step was to prepare a solid model
are asbestos, metals, non -asbestos organic such as palm of the brake shoe. This was carried out by using Solidworks
kernel shell (PKS), and ceramics. Asbestos during 2014 Software.
application releases the hazardous gases, which causes
damage to the health. The main element is used for brake Analysis: Brake shoe finite element analysis is done through
lining from palm kernel shell (PKS) which is agro-waste. Solidworks 2014 software. Both stress analysis and
The average disk temperature and average stopping time for deformation analysis is done under different braking time
pass is increased and it has poor dimensional stability. and operational conditions.
Hence it has lost favour and several alternative materials are
being replaced these days. [8] Boundary Conditions: For Stress analysis, pressure is
applied on the external surface of the round face of the brake
Pascu LV et al (2015) - For making brake shoes are used shoe.Both the ends of the shoe is fixed, as we know that, the
frequently gray cast iron with lamellar graphite and nodular adjuster side end of shoe is fixed but expander side of the
cast iron, which have a good thermal conductivity, good shoe is movable due to cam, but we consider it as fixed,
mechanical properties, good wear resistance. Cast iron brake because when the cam is rotated, the shoe will expand to the
block enjoys many advantages including hardness, impact drum and stick with the drum tightly (at full load condition),
strength and so on. [9] then it will be the worst condition, so at this situation we can
consider that expander side as fixed.
3. Methods and Material
Force calculation
To create the cad model of the brake shoe we find the Force exerted on paddle will rotate the cam, that force exerts
existing brake shoe of Hero Honda Splendor from market the pressure on brake shoe so brake shoe will exert same
for reverse engineering. We can measure all the visible fore on drum, so that according to newton’s third law the
dimensions manually with specified measuring instruments same reaction force will exert on brake shoe. For the
to create accurate and scaled model. To find out accurate calculation on force and pressure we have to define the
feature location like holes plane angles etc.CMM is done. loadings and other specification of brake shoe.
Using CAD software we can create CAD model of brake Weight of bike = 112kg
shoe as per measurement data we Import the CAD Model Maximum payload = 130kg
(IGES) in the Solidworks for pre-processing and then the Net weight= 242kg ≃ 250kg
stress and deformation analysis is done on the brake shoe. Maximum velocity of bike = 95km/hrs. Or 26.388m/sec.
The Analysis involves the discretization called meshing, Stopping time = 3sec
boundary conditions and loading. For analysis we take Forces on braking system = m (rω)/t = 250*26.388/3 =
Aluminium with aluminium alloys as the material. The 2199N
Aluminium has been selected based on the properties Forces on each brake drum = 2199/2 = 1099.5N
required for the existing brake shoe. The aluminium alloys According to Newton’s third law,
has been selected as matrix for manufacturing the MMC Forces on brake drum = Forces on brake shoe
based on the ease of manufacturing. [10] Therefore, Forces on each brake shoe = 1099.5/2 = 549.75N
Contact area of brake shoe on brake drum:-
Specifications of brake shoe Length of arc, L = rθ
Inner diameter of drum (mm) = 110 L = 52.5*120*(π/180) = 109.9557mm
Contact an angle per shoe = 120 Width of shoe = 25mm
Width of Shoe (mm) = 25 Contact area of shoe = 109.9557*25 = 2748.893572mm² =
Thickness of lining (mm) = 4 2.74889*10-3m
Diameter of Anchor pin (mm) = 8.5 Pressure on shoe = Force/Area = 549.75/2.74889*10 -3
Thickness of Cam (mm) = 6.22 = 199989.8141N/m²= 0.119993732MPa ≃
Outer diameter of hub (mm) = 46.46 0.12MPa
No. of shoes = 2
Table I: Force table
Material properties of brake drum Velocity of Bike (Km/hr.) Stopping time(sec) Forces(N)
Material Density Tensile Young’s Modulus Poisson’s 95 3 549.75
(g/cm3) Strength (MPa) (x103 N/mm2) ratio 95 7 235.607
LM28 2.68 165 82 0.33 30 3 173.6041667
HT200 7.20 170 80 0.25 30 7 74.40178571
A6063 2.69 165 68.3 0.33

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Paper ID: ART2020286 10.21275/ART2020286 581
 International Journal of Science and Research (IJSR)
ISSN: 2319-7064
ResearchGate Impact Factor (2018): 0.28 | SJIF (2018): 7.426

4. Results and discussion doing analysis by taking different materials. We found the
displacement 0.0248, 0.006331, 0.01041 mm, and stresses
Material Displacement (mm) Stresses (N/mm2) 0.021581-14.434, 0.026153-14.435,0.019-13.229 N/mm2on
LM28 0.0248 0.021581-14.434 LM28, HT200 and A6063 materials respectively.
HT200 0.006331 0.026153-14.435
A6063 0.01041 0.019-13.229 5. Conclusion
After doing analysis on brake shoe model, we found the The deformation and the stress induced in the aluminium
above result which is mentioned in tabular form. Our aim is alloy and grey cast iron brake shoe during the application of
to suddenly stop the vehicle at maximum deceleration. We brake force have been determined using finite element
took stopping time is 3 seconds as sudden stoppage, then we analysis. It is observed from the analysis that the
found different displacement and stresses on shoe after deformation in Grey cast iron brake shoe is considerably less
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 International Journal of Science and Research (IJSR)
ISSN: 2319-7064
ResearchGate Impact Factor (2018): 0.28 | SJIF (2018): 7.426
than the Aluminium alloy brake shoe. The stresses in the
Grey cast iron and Al alloy brake shoe are found to be
almost same. There is negligible variation in them. Hence,
the required factor of safety is maintained in both the Grey
cast iron and Al alloy brake shoe. While braking from a
speed of 95km/h at sudden braking, we found that the
chances of deformation in brake shoe is more on the edges
of upper surface of the shoe where force is applied. The
Aluminium alloys brake shoe has comparatively less weight
than Grey cast iron brake shoe. From the above
observations, it is concluded that the Aluminium alloy brake
shoe has less weight, and easily available in the market.
Hence, the aluminium alloys can be a better candidate
material for the brake shoe applications of light commercial
vehicles.

References
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[2] By Rolla H. Taylor and William L. Holt “Effect of
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[3] Akshat Sharma, Amit Kumar Marwah “Braking
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[4] Anup Kumar and R. Sabarish “Structural and Thermal
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[7] K Radhakrishna, (2008) “Hardness and Wear
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[10] Meenakshi Kushal, Suman Sharma, “Optimization of
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