MACHINE DESIGN - An Integrated Approach, 4th Ed.

Case Study 1A-1

CASE STUDY 1A

Bicycle Brake Lever Loading Analysis

Problem: Determine the forces on the elements of the bicycle brake lever assembly shown
in Figure 3-1 during braking.
Given: The geometry of each element is known. The average human's hand can
develop a grip force of about 267 N (60 lb) in the lever position shown.
Magnitude of handle force Fb2 Fb2  267  N
Direction of handle force Fb2 θb2  270  deg
Direction of cable force Fc2 θc2  184  deg
Direction of cable force Fcable θcable  180  deg

Positon vector components

Rb2x  39.39  mm Rc2x  50.91  mm R12x  47.91  mm
Rb2y  2.07 mm Rc2y  4.66 mm R12y  7.34 mm

R21x  7  mm Rb1x  47.5 mm R31x  27 mm

R21y  19 mm Rb1y  14 mm R31y  30 mm

Assumptions: The accelerations are negligible. All forces are coplanar and two-dimensional.
A class 1 load model is appropriate and a static analysis is acceptable. The
higher applied load will be used as a worst case, assuming that it can be
reached before bottoming the tip of the handle on the handgrip. If that occurs,
it will change the beam's boundary conditions and the analysis.
Solution: See Figures 3-1, 3-2, Table 3-2 parts 1 and 2, and Mathcad file CASE1A.
1. Figure 3-1 shows the handbrake lever assembly, which consists of three subassemblies: the handlebar (1), the
lever (2), and the cable (3). The lever is pivoted to the handlebar and the cable is connected to the lever. The
cable runs within a plastic-lined sheath (for low friction) down to the brake caliper assembly at the bicycle's
wheel rim. The user's hand applies equal and opposite forces at some point on the lever and handgrip. These
forces are transformed to a larger force in the cable by reason of the lever ratio of part 2.

Figure 3-1 is a free-body diagram of the entire assembly since it shows all the forces and moments acting on it
except for its weight, which is small compared to the applied forces and is thus neglected for this analysis.
The "broken away" portion of the handlebar provides internal x and y force components and a moment.
These are arbitrarily shown as positive in sign. Their actual signs will "come out in the wash" in the
calculations. The known applied forces are shown in their actual directions and senses.

2. Figure 3-2 shows the three subassembly elements separated and drawn as free-body diagrams with all relevant
forces and moments applied to each element, again neglecting the weights of the parts. The lever (part 2) has
three forces on it, Fb2, Fc2, and F12. The two-character subscript notation used here should be read as, force
of element 1 on 2 (F12) or force at B on 2 (Fb2), etc. This defines the source of the forces (first subscript) and
the element on which it acts (second subscript).

This notation will be used consistently throughout this text for both forces and position vectors such as Rb2,
Rc2, and R12 in Figure 3-2, which serve to locate the above three forces in a local, nonrotating coordinate
system whose origin is at the center of gravity (CG) of the element or subassembly being analyzed. (See foot
note on page 108 of the text).

On this brake lever, Fb2 is an applied force whose magnitude and direction are known. Fc2 is the force in the
cable. Its direction is known but not its magnitude. Force F12 is provided by part 1 on part 2 at the pivot pin.

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MACHINE DESIGN - An Integrated Approach, 4th Ed. Case Study 1A-2

Its magnitude and direction are both unknown. We can write equations 3.3b for this element to sum forces
in the x and y directions and sum moments about the CG. Note that all unknown reactive forces and
moments are initially assumed positive in the equations. Their true signs will come out in the calculation.

ΣFx = Fb2x  Fc2x  F12x = 0

ΣFy = Fb2y  Fc2y  F12y = 0 (a)

ΣMz =  R12  F12   Rb2  Fb2   Rc2  Fc2 = 0

The cross products in the moment equation represent the "turning forces" or moments created by the
application of these forces at points remote from the CG of the element. Recall that these cross products can
be expanded to

ΣMz =  R12x F12y  R12y F12x   = 0

  Rb2x Fb2y  Rb2y Fb2x  (b)
  R  F  R  F  
 c2x c2y c2y c2x 

We have three equations and four unknowns (F12x, F12y, Fc2x, Fc2y) at this point, so we need another equation. It
is avalable from the fact that the direction of Fc2 is known. (The cable can pull only along its axis). We can
express one component of the cable force Fc2 in terms of its other component and the known angle c2 of the
cable.
Fc2y = Fc2x tan  θc2 (c)

We will now use a Mathcad solve block to solve equations a through c.

Calculate components of Fb2

Fb2x  Fb2 cos θb2 Fb2x  0  N

Fb2y  Fb2 sin θb2 Fb2y  267  N

Guess F12x  1000 N Fc2x  1000 N

F12y  1000 N Fc2y  1000 N
Given
Fb2x  Fc2x  F12x = 0  R12x F12y  R12y F12x   = 0
  Rb2x Fb2y  Rb2y Fb2x 
Fb2y  Fc2y  F12y = 0   R  F  R  F  
 c2x c2y c2y c2x 

Fc2y = Fc2x tan  θc2

 F12x 
F 
 12y   Find  F F F F 
 Fc2x  12x 12y c2x c2y

 
 Fc2y 
Components of the unknown forces F12, and Fc2
F12x  1909 N Fc2x  1909 N

F12y  400  N Fc2y  133  N

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MACHINE DESIGN - An Integrated Approach, 4th Ed. Case Study 1A-3

3. Part 3 in Figure 3-2 is the cable that passes through a hole in part 1. This hole is lined with a low friction
material, which allows us to assume no friction at the joint between parts 1 and 3. We will further assume
that the three forces F13, Fc3, and Fcable form a concurrent system of forces acting through the CG and
thus create no moment. With this assumption, only a summation of forces is necessary for this element.
ΣFx = Fcablex  F13x  Fc3x = 0
(d)
ΣFy = Fcabley  F13y  Fc3y = 0

Using Newton's third law, we have Fc3x  Fc2x and Fc3y  Fc2y
.
We also assume that the cable entering from the left is horizontal and that the reaction F13 is vertical, thus
Fcabley  0  N and F13x  0  N (e)

We can now solve for the forces on part 3 directly,

Fcablex  F13x  Fc3x Fcablex  1909 N

F13y  Fcabley  Fc3y F13y  133  N

4. The assembly of elements labeled part 1 in Figure 3-2 has both force and moments on it (i.e., it is not a concurre
system), so the three equations 3.3b are needed.

ΣFx = F21x  Fb1x  F31x  Px  Fsheathx = 0

ΣFy = F21y  Fb1y  F31y  Py = 0 (f)

ΣMz = Mh   R21  F21   Rb1  Fb1   R31  F31  = 0

  Rp  Fp   Rd  Fsheath

Expanding cross products in the moment equation gives the moment magnitude as

ΣMz = Mh   R21x F21y  R21y F21x  = 0

  Rb1x Fb1y  Rb1y Fb1x  
  R31x F31y  R31y F31x   (g)
  R  F  R  F   
 Px Py Py Px 
  0  Rdy Fsheathx 
Using Newton's third law, we have
F31x  F13x F21x  F12x Fb1x  Fb2x
(h)
F31y  F13y F21y  F12y Fb1y  Fb2y
Fsheathx  Fcablex

Given RPx  27 mm RPy  0  mm

Rdx  41 mm Rdy  27 mm

We will now use a Mathcad solve block to solve equations (f) through (h).

Guess Px  1000 N Mh  100  N  m

Py  0  N

Given F21x  Fb1x  F31x  Px  Fsheathx = 0 F21y  Fb1y  F31y  Py = 0

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MACHINE DESIGN - An Integrated Approach, 4th Ed. Case Study 1A-4

Mh   R21x F21y  R21y F21x  = 0  Px 

  Rb1x Fb1y  Rb1y Fb1x    
  R31x F31y  R31y F31x    Py   Find  Px Py Mh
  R  P  R  P    M 
 Px y Py x   h
  0  N  m  Rdy Fsheathx 

5. Summarizing, the results obtained for a grip force Fb2  267  N are:

Handlebar (1) Fb1x  0  N Fb1y  267  N

F21x  1909 N F21y  400  N
F31x  0  N F31y  133  N

Px  0  N Py  0  N
Mh  9.0 N  m

Lever (2) Fc2x  1909 N Fc2y  133  N

F12x  1909 N F12y  400  N

Cable (3) Fc3x  1909 N Fc3y  133  N

F13x  0  N F13y  133  N
Fcablex  1909 N Fcabley  0  N

6. A summary of the results for the given dimensions is given above in step 5, assuming a 267-N (60-lb) force
applied by the person's hand normal to the brake lever. The force generated in the cable (Fcable) is then 1909
N (429 lb), the reaction force against the handlebar (F21) is 1951 N (439 lb) at -168 deg.

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