IPASJ International Journal of Mechanical Engineering (IIJME)

A Publisher for Research Motivation........

Volume 3, Issue 12, December 2015

Web Site: http://www.ipasj.org/IIJME/IIJME.htm

Email: editoriijme@ipasj.org
ISSN 2321-6441

Failure Analysis of Brake Shoe in Indian

Railway Wagon
Ambikaprasad.O.Chaubey1, Prof.Abhijeet.A.Raut2
1

Department of mechanical engineering, GHRCE, Nagpur

Department of mechanical engineering, GHRCE, Nagpur

ABSTRACT
Train braking is a very complex process in overall railway assembly, breaking system has a great importance & contribution in
safety. This complexity results from the fact that during braking occur numerous phenomena of different kinds - mechanical,
thermal, pneumatic, electrical, etc. The following drawbacks due to existing brake force on the brake blocks - thermal cracks
on wheel tread, brake binding and reduced life of brake block.In this project we are going to do failure analysis on brake shoe
by stress analysis and thermal analysis using software and after that we will suggest alternative solution to avoid or reduce the
problems.

Keywords:- alternative solution, failure analysis, brake force, fact, reduced life.

1. INTRODUCTION
Several aspect of the tread braking system, important for the dimensioning of railway brake shoe pad, are assessed,
such as brake block material, residual stresses and temperature gradients through wheel disc.
In this project we are going to do failure analysis on brake shoe by stress analysis and thermal analysis using
software and after that we will suggest alternative solution to avoid or reduce the problems.

Fig1:-Brake shoe on wagon wheel

2. FAILURE OF BRAKE SHOE
DEFECT TYPE
1. Transverse cracks on wheel tread
2. Wheel fracture coming out of field side chamber
3. Slots on wheel tread
4. Grooves, comb indentation on wheel tread
PROBABLE CAUSE
1. Breaking heat from shoe brakes, plastic deformation of surface layer
2. Brake shoe offset through rim face, overheating, dynamic loads, fatigue process
3. Brake shoe offset
4. Wheel treads warming-up under braking, abrasive material

Volume 3, Issue 12, December 2015

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IPASJ International Journal of Mechanical Engineering (IIJME)

A Publisher for Research Motivation........

Volume 3, Issue 12, December 2015

Web Site: http://www.ipasj.org/IIJME/IIJME.htm

Email: editoriijme@ipasj.org
ISSN 2321-6441

Fig 4: Various Condition of Brake Shoe

Fig 5: Condition of Wheel

Defects Due to Phenolic Resin
Brake fade is the reduction in stopping power that can occur after repeated or sustained application of the brakes,
especially in high load or high speed conditions.
On release of the brakes and cooling to the room temperature, the regain of the original magnitude of it is referred
as recovery.
Normally the brake pads are highly rated by their Low fade and high recovery.
In Non asbestos semi metallic friction composites, resin, friction dust and some organic fibres that are most
vulnerable to thermal degradation undergo charring, which results in glazing and deterioration in friction
performance.
Efforts are reported on exploration of others resins as binders such as epoxy, silicone, phenolics, thermoplastic
polyimide, cyanate ester, etc. .
The objective of the work reported here was to investigate the properties of phenolic resin with some different
resin having better quality properties so that composite of brake shoe material efficient & durable.

3. LIFE OF BRAKE SHOE

NUMBER OF BRAKE SHOE IN VARIOUS TRAINS

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IPASJ International Journal of Mechanical Engineering (IIJME)

A Publisher for Research Motivation........

Volume 3, Issue 12, December 2015

Web Site: http://www.ipasj.org/IIJME/IIJME.htm

Email: editoriijme@ipasj.org
ISSN 2321-6441

COMPARISON OF EXISTING & PROPOSED RESINS PROPERTIES

We will focus on three parameter in the composition of resin material

INVOLVEMENT OF CAD SOFTWARE

Complete model of device can be done by Cero, Pro-E software.
Analysis of load stresses on brake shoe by means of ANSYS.
Analysis of thermal stress on the brake shoe by means of ANSYS.
The best material selection for brake shoe on the basis of load analysis in wheel of train.

4. BRAKE SHOE
According to the existing air brake system of Railway coach the brake force applied per one brake block is 2.187 tons.
The following drawbacks due to existing brake force on the brake blocks - thermal cracks on wheel tread, brake binding
and reduced life of brake block. An overview of design methods for thread braking systems is given with special focus
on the braking capacity. Several aspect of the tread braking system, important for the dimensioning of railway brake
shoe pad, are assessed, such as brake block material, residual stresses and temperature gradients through wheel disc.
The influence of heat partitioning between wheel, brake block and rail on wheel temperature for different braking cycle
is consider. The existing air brake system of Railway coach has the following drawbacks due to excessive brake force
on the brake blocks - thermal cracks on wheel tread, brake binding and reduced life of brake block. To validate the
strength of train brake, Structural and Modal analysis are to be done on the train brake. In structural analysis, ultimate
stress limit for the design is found and in modal analysis.

6. MATERIAL COMPOSITION OF BRAKE SHOE

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IPASJ International Journal of Mechanical Engineering (IIJME)

A Publisher for Research Motivation........

Volume 3, Issue 12, December 2015

Web Site: http://www.ipasj.org/IIJME/IIJME.htm

Email: editoriijme@ipasj.org
ISSN 2321-6441

7. MATERIAL PROPERTIES OF BRAKE SHOE PAD

Density of brake disc
material
Specic heat of brake
disc material
Thermal conductivity
of brake disc material
Density of brake pad

7246(kg/m3)

Specic heat of brake

pad
Thermal conductivity
of brake pad
Average friction
coefficient

1090 (J/kg K)

500 (J/kg K)
58 (W/m K)
2180 (kg/m3)

1.67 (W/m K)
0.32 (m)

SOLID MODEL DIAGRAM OF BRAKE SHOE

PROPOSED MODEL OF BRAKE SHOE

9. CONCLUSION
Two composites, based on two variant in resin formulations, were evaluated under fade and recovery tests and the
following conclusions were obtained. The composite based on alkyl benzene modified resin proved better from a
frictional point of view.

REFERENCES
[1] Dr. D.S. Deshmukh & Jha Shankar Madanmohan Design Evaluation and Material Optimization of a Train
Brake in International Journal of Research Studies in Science, Engineering and Technology [IJRSSET] Volume
1, Issue 2, May 2014, PP 45-49.
[2] Sevvel , Nirmal Kannan , Mars Mukesh , Innovative Electro Magnetic Braking System International Journal of
Innovative Research in Science, Engineering and Technology , An ISO 3297: 2007 Certified Organization ,
Volume 3, Special Issue 2, April 2014.
[3] P. Balashanmugam, K.Balasubramaniyan, G.Balasubramaniyan,S.Vinoth , Fabrication Of High Speed Indication
And Automatic Pneumatic Braking System , International Journal of Engineering Trends and Technology
(IJETT) Volume 5 number 1 Nov 2013

Volume 3, Issue 12, December 2015

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IPASJ International Journal of Mechanical Engineering (IIJME)

A Publisher for Research Motivation........

Volume 3, Issue 12, December 2015

Web Site: http://www.ipasj.org/IIJME/IIJME.htm

Email: editoriijme@ipasj.org
ISSN 2321-6441

[4] M.A.Saibalaji ,Dr. K.Kalaichelvan Effect Of Alkyl Benzene Modified Resin Matrix In Relation To The Friction
Stability In A Non Asbestos Disc Brake Pad -International Conference On Advances In Engineering, Science And
Management March IEEE,2012.
[5] Min-Soo Kim Development of the Braking Performance Evaluation Technology for High-speed Brake
Dynamometer International Journal Of Systems Applications, Engineering & Development Issue 1, Volume
6,2012
[6] Min-soo Kim , Dynamometer Tests Of Brake Shoes Under Wet Conditions For The High Speed Trains,
International Journal Of Systems Applications, Engineering & Development Issue 2, Volume 5, 2011.
[7] Hyuncheol Kim And Whoi-Yul Kim Automated Inspection System For Rolling Stock Brake Shoes Transactions
On Instrumentation And Measurement, IEEE AUGUST 2011
[8] Shahab Teimourimanesh , Roger Lunden , Tore Vemerssionm Bracking capacity of railway wheels-state-of-theart-survey 16th International Wheelset Congress (IWC16), Cape Town (RSA) March 2010
[9] .Hongbing Qiao, Bin Gong, Study Of Safety Monitoring System For Mine Hoisting Machine Brake Shoe
Mechanical Electrical And Information Engineering IEEE .2010
[10] .Jungwon Hwang1, Hyuncheol Kim Image Analysis System For Measuring The Thickness Of Train Brakes
Eastern European Conference On The Engineering Of Computer Based Systems, IEEE 2009
[11] .Anand Prabhakaran Simplified Representation Of Rigging Efficiency In Brake Force Calculation,, Joint Rail
Conference, ASME ,April 4-6, 2006,

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