Volume 6, Issue 1 MAY 2017

DESIGN AND ANALYSIS OF DRUM BRAKES

1
DVSRBM SUBRAMANYAM2L.SRAVANI.

1
Associate Professor of Mechanical Engineering, nalanda institute of engineering and technology, satenapalli,
Guntur, Andhra Pradesh 522438
2pg Scholar, Departmentof Mechanical Engineering,nalanda institute of engineering and technology, satenapalli,
Guntur, Andhra Pradesh 522438

ABSTRACT rate of descent is controlled. The energy absorbed by

brakes is dissipated in the form of heat. This heat is
A brake is a mechanical device which inhibits
dissipated in the surrounding atmosphere to stop the
motion. A drum brake is a brake that uses friction
vehicle, so the brake system should have following
caused by a set of shoes or pads that press against a
requirements:
rotating drum-shaped part called a brake drum.
 The brakes must be strong enough to stop
The brake drum is a critical component that
the vehicle with in a minimum distance in an
experiences high temperatures and develop thermal
emergency.
stresses during application of brakes. In addition, the
 The driver must have proper control over
application of shoe pressure gives rise to mechanical
the vehicle during braking and vehicle must
loads. So the analysis takes into account both the
not skid.
thermal stresses and mechanical stresses together.
 The brakes must have well anti fade
Brakes in cars and trucks are safety parts. characteristics i.e. their effectiveness should
Requirements not only in performance but also in not decrease with is constant prolonged
comfort, serviceability and working lifetime are high application.
and rising. i.e. the brake pad with the friction  The brakes should have well anti wear
material, the counter body and caliper, can be properties.The important requirements of the
modeled. brake drum are following:
So in this project we design the model of drum brake  It should provide a surface having well anti
(drum, & pads) in solid works 2016 and structural wear qualities.
and thermal analysis are performed in ansys work  It should allow the optimum rate of heat
bench software transfer.
1. INTRODUCTION  Heat is generated during each brake
A brake is a device which is used to bring to rest or application and it must be dissipated to the
slow down a moving body. Safe operation of vehicle atmosphere immediately, because the next
demands dependable brakes is required to absorb the brake application would again produce more
kinetic energy of the moving parts or the potential heat. Any excess heating of brakes would
energy of the object being lowered by host when the cause the drum to expand resulting in loss of

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effective pedal travel and fading of brake depends on the various factors such as friction,
lining. surface roughness, speed, and others.
 It should have sufficient strength but
Ray W.Murphy et al [5] in their report concluded that
minimum weight.
the braking efficiency of trucks and can be improved
 It should be able to be accommodated within
by careful distribution of braking effort among the
the wheel space available.
axles of the vehicle. Mr Songwut
2. LITERATURE SURVEY
Allan Michael Lang [1] in his research concluded Mongkonlerdmanee [6] in his thesis concluded that to

that no simple relationship exists between the natural achieve maximum brake efficiency, vehicle geometry

frequencies of the brake components and the squeal and real friction coefficient should be considered to

frequency and during squeal both the drum and shoes design the brake proportion on each axle and the

hold complex modes, which can be best visualized as deceleration and braking distance on the front axle

the superposition of pairs of similar normal modes was better than those on the other axles because of

phase shifted both spatially and in time relative to the additional vertical load from the dynamic

each other. Mohd transfer.

Zald Bin Akop [2] in his project concluded that Muhammad najib bin abdulhamid[7] conducted the

safety aspect in automotive engineering has been experimental analysis on drum brake and FEA

considered as a number one priority in development analysis and concluded that improved material

of new vehicle and it is a must for all vehicles to have performs better.

proper brake system.

Ramesha.D.K et al [3] in his thesis concluded that the Kang and Cho [8] investigated thermal deformation

maximum temperature obtained for aluminum alloy and stress analysis of brakes by finite element

brake drum is less as compared to the cast iron brake method for ventilated disk and solid disk. By

drum for a truck. Also, concluded that thermal comparing the result of maximum temperature in the

deformation is less for aluminum alloy brake drum braking process, the ventilated disk showed a lower

than the cast iron brake drum. As his study states that temperature than the solid disk. The effect of

the weight of Aluminum is lesser than the Cast iron, temperature increase and decrease, depending on the

it is better to use the Aluminum material in the vent area generated in the flange part of the disk.

construction of brake drum. Analysis of design parameter effects on vibration

modes of a motorcycle drum brake and brake shoe
NurulhudaBinti Khalid [4] In his project concluded using the finite element method were also carried out
that the temperature changes on the brake drum . They reported that the drum brake had 42 mode
during the deceleration providing the heat shapes in the frequency range of 100 Hz to 12 kHz.
distribution and the distribution of temperature Most of the mode shapes occurred in pair (repeated

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root). The brake shoe wasfound to have 10 modes
shapes in the frequency range analyzed.
3.PROBLEM STATEMENT
3.0 problem statement:Drum Brake and Drum
Brake Pad are connected on the wheels of automobile
for the braking of the vehicle on road. The drum
brake and brake pad under goes several rough
conditions on road different types of loads and
temperatures will be acting on the brakes. The
brakes are surely essential for the effective stopping
of the vehicle. Here in this project we are taking the
load condition as 1.5Mpa pressure on the face of the
drum Brake and also the Drum brake pad. We are
using three different materials i.e aluminium alloy,
carbon steel and aluminium metal matrix composite.
Doing the analysis on three different materials using
the load condition we will find which is the best
appropriate material for use. Also when the brake is
applied due to the friction between the drum and the
brake pad certain heat is distributed and released.
Here we consider the thermal conditions to be as
90deg temperature and 22deg convection. Thus
applying all the load and thermal conditions for three
different materials Drum Brake and BrakePad we
conclude the best desirable materials.
3.1 objectives of project
The objectives of the project are as follows
(i) To develop structural modeling of Drum Brake
and BrakePad.
(ii) To perform finite element analysis of Drum
Brake and Brake Pad.
(iii) Suitable material study.
(iv) Study of load and Thermal factors.
(v) Study of stress, strain deformation, temperature
and heat flux induced in the Drum Brake and Brake
Pad.
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(vi) To develop structural optimization model of
connecting rod
4. DESIGNING OF ADRUM BRAKESBY
USING SOLID WORKS
4.1 Introduction To Solidworks :
Solidworks mechanical design automation software is
a feature-based, parametric solid modeling design
tool which advantage of the easy to learn windows TM
graphical user interface. We can create fully associate
3-D solid models with or without while utilizing
automatic or user defined relations to capture design
intent.
Parameters refer to constraints whose values
determine the shape or geometry of the model or
assembly. Parameters can be either numeric
parameters, such as line lengths or circle diameters,
or geometric parameters, such as tangent, parallel,
concentric, horizontal or vertical, etc. Numeric
parameters can be associated with each other through
the use of relations, which allow them to capture
design intent
A Solid Works model consists of parts, assemblies,
and drawings.
 Typically, we begin with a sketch, create a
base feature, and then add more features to
the model. (One can also begin with an
imported surface or solid geometry).
 We are free to refine our design by adding,
changing, or reordering features..
4.2 Design procedure of Drum Brakes
For designing the Drum Brakes the following
procedure has to be follow
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Making Circular Pattern

4.3 Design procedure of Drum Brake Pad

For designing the Drum Brakes the following

procedure has to be follow

Brake shoe lining

Dimensions of Drum Brake

Sketch and Extrude

Sketch & Revolve

.Brake Pad
Make Shell

Extrude Cut All Views of Brake Pad

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5. ANALYSIS DEFINATION &STEPS:

The steps needed to perform an analysis depend on
the study type. You complete a study by performing
the following steps:
 Create a study defining its analysis type and
options.
 If needed, define parameters of your study.
A parameter can be a model dimension,
Figure5.1 structural analysis of Drum Brake
material property, force value, or any other
input.
 Define material properties.
 Specify restraints and loads.
 The program automatically creates a mixed
mesh when different geometries (solid,
shell, structural members etc.) exist in the
model.
 Define component contact and contact sets.
Figure5.2 structural analysis of Brake Pad
 Mesh the model to divide the model into
many small pieces called elements. Fatigue 5.2 Materials and their properties
and optimization studies use the meshes in
referenced studies.
 Run the study.
 View results.
5.1 Analysis on Drum Brakes by using ansys 14.5
work bench software
The analysis of Drum brake and Brake pad
models are carried out using ANSYS software
usingFiniteElement Method. Firstly the model files
prepare in the SOLIDWORKS SOFTWARE.
Then are exported to ANSYS software as an IGES
5.3 Load & fixed support
files as shown in figure
• Fixed support

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It's done with a variety of tools & options available in

the software. The results are calculated bysolving the
relevant governing equations numerically at each of
the nodes of themesh. The governing equations are
almost always partial differential equations,
and Finite element method is used to find solutions to
such equations. The pattern and relative positioning
of the nodes also affect the solution, the
computational efficiency & time.

• Load
Load at 1.5MPA

Mesh Type: Tetrahedral

No. of nodes: 16190
No. of elements: 8821
6. STRUCTRUALANALYSISRESULTS FOR
DRUM BRAKE
6.1 Material: Aluminium Alloy
Maximum Stress

5.3 Meshing
Meshing is probably the most important part in any
of the computer simulations, because it can show
drastic changes in results you get. Meshing means
Total Deformation
you create a mesh of some grid-points called 'nodes’.

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6.3 Material: Aluminium Metal Matrix

Maximum Strain Maximum Stress

Total Deformation
6.2 Material: Carbon Steel
Maximum Stress

Maximum Strain
Total Deformation

7. STRUCTRUALANALYSIS RESULTS FOR

Maximum Strain DRUM BRAKE PAD
7.1Material:Aluminium Alloy
Stress

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Total Deformation Maximum Strain

Maximum Strain 7.3Material:Aluminium Metal Matrix

Stress

7.2Material:Carbon Steel
Stress
Total Deformation

Total Deformation Maximum Strain

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8. THERMAL ANALYSIS RESULTS FOR 8.2 Material: Carbon Steel

DRUM BRAKE Temperature Distribution

Temperature 90 c

Heat Flux
Convection 22deg

8.3 Material: Aluminium Metal Matrix

TemperatureDistribution
8.1 Material: Aluminium Alloy
Temperature Distribution

Heat Flux

Heat Flux

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9.2 Material: Carbon Steel

9. THERMAL ANALYSIS RESULTS FOR Temperature Distribution
DRUM BRAKE PAD
Temperature 90 c

Heat Flux

Convection 22 deg

9.3 Material: Aluminium Metal Matrix

Temperature Distribution

9.1 Material: Aluminium Alloy

Temperature Distribution

Heat Flux

Heat Flux

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RESULT TABLE
Results for Drum Brake

For comparisons of the results obtained From the

static analysis result tables it is concluded that
42CrMo4 show least stress and least deformation &
strain value on same static load condition.

From the Modal analysis result tables it is concluded

that 42CrMo4 shows Less deformation results for
given frequency. Hence for both Structural and
Modal Analysis 42CrMo4 (Special Alloy Steel) it is
best suitable material for connecting rod.
Results for Brake Pad

CONCLUSION

 Modeling and analysis of drum brakes and

drum brake pads is done.

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 Modeling of drum brake and drum brake  Thus the modeling and analysis of drum
pads are done in solid works 2016 design brake is done with different materials at
software. different boundary conditions.
 Thus both files are saved as igs to import
into ansys workbench REFERENCES
 Structural and thermal analysis is carried on
[1]. Anup Kumar and R. saharish. Structural and
drum brake and drum brake pads in ansys
Thermal Analysis of Brake Drum. Middle East
workbench
Journal of Scientific Research Vol20. (8). IDOSI
 First structural analysis of pressure of 1.5
Publication. Pp 1012-1016. . 2014.
Mpa is applied with three different materials
[2]. Brake Drum. Available at
such as aluminum alloy, Carbon Steel,
en.wikipedia.org/wiki/Drum_brake. Cited March
aluminum Metal matrix.
2015.
 Maximum stress, deformation, strain,
[3]. Frank Kreith. Mechanical Engineerimg Handle
Temperature and Heat flux are found and
Book. Boca Raton: CRC Press LLC. Pp 4-7. 1999.
tabulated.
[4]. Daniel Dannelley, John Baker, Clark K. Midkeff,
 Next steady state thermal analysis of drum
Robert P. Taylor, Keith A. Woodburry. Enhancement
brake with three different materials
of Extended Surface Heat Transfer Using Fractal-like
aluminum alloy, Carbon Steel, aluminum Geometry. Department of mechanical Engineering,
Metal matrix at 900c temperature and 220c
Graduate School of the University of Alabama. Pp
ambient temperature of convection is
14-15. 2013.
applied
[5]. Fred Puhn. Brake Handbook. 2rd edition.HP
 Temperature distribution and total heat flux Books Pp4, 15-21. 1985.
are obtained and tabulated. [6]. Giri N.K. Automobile Technology. Sixth edition
 Thus the stress, strain, shear stress and total (reprint). Khanna Publisher. Pp 1269-1272.2012.
deformations values are obtained and [7]. James Carvill. Mechanical Engineer’s Data
tabulated. Handbook. First Edition. Butterworth Heinemann
 From result we can conclude that beside Publication. Pp129-131.1993.
general material, aluminum metal matrix
(ks1275) which is economically less cost [8]. Karim Nice. How Drum Brakes Works.
and less weight ratio gives nearly same Available at www.howstuffworks.com/auto-
stress and deformation value in static parts/brake/brake-types/drum-brake 1.htm. cited
analysis and giving good thermal March 2015
distribution value so it can also use as the
material for drum brake beside general [9]. Kicreyco Brake Drum Catalog. Kic Holding

materials. IncPp 1-12. Available at www.kic-group.com. Cited

April 2015.

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[10]. Narang G.B.S. Automobile Engineering. First

Edition. Kahanna Publisher. Pp 275-277. 1977.
[11]. PrabalTalukdar Design of Heat Sink (1-3).
Thermal System simulation (2-0-2), Department of
mechanical Engineering, IIT Delhi.

AUTHORS

1.DVSRBM SUBRAMANYAM

Associate Professor of Mechanical Engineering,

College name:Nalanda institute of

engineeringand technology,Village:kantepudi
Mandal:sattenpalli, Dist:guntur
A.P, India,Pin:522438
Emailid:SUBHRAMANYASHARMA@GMAIL.COM

2.L.SRAVANI
Department ofMechanical Engineering,

College name:Nalanda institute of

engineeringand technology, Village:kantepudi

Mandal:sattenpalli, Dist:guntur

A.P, India,Pin:522438
Email id: sravanilakshmi22@gmail.com

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