16.

Clutches and Brakes

Objectives

Introduction
Clutch is a device that connects and disconnects two collinear shafts.
Similar to couplings Friction and hence heat dissipation

Recognize the basic geometries of clutch and brake systems. Calculate the frictional forces and torque capabilities in brake systems. Understand the principles of heat generation and heat removal from brake systems. Calculate frictional brake horsepower and recognize how to use it.
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Purpose of a brake is to stop the rotation of a shaft. Braking action is produced by friction as a stationary part bears on a moving part.
Heat dissipation is a problem Brake fade during continuous application of braking due to heat generated

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Plate clutch

Cone clutch

Uses Spring loaded flat surfaces Transmit power in either direction

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Uses tapered friction surfaces Easy to engage

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Caliper disc brake

Drum brake

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Drum brake

Block brake Wagon brake

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Band brake

Fig. 16-7 Disc brake 16-

Belt wrapped around the wheel

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Friction Materials
Asbestos fibers embedded in an epoxy-type material epoxyGood thermal properties High friction coefficient (0.35 to 0.50) Environmental concerns

Polymer compounds with impregnated material

Metal shavings Graphite Sintered iron

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Torque and Forces

Sliding friction Friction force, Ff = f N f = coefficient of friction N = normal force

Plate type clutch

Rotating torque, Tf = Ro = outside radius Ri = inside radius
R + Ri f N o 2

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Plate type clutch

Friction power can be calculated as, Pf =
Tf n 63,000

Example Problem 16-1: Torques and Forces on Clutches and Brakes

A plate-type clutch has the following properties: Ro = 12 in Ri = 9 in engagement force of 120 lb (normal force) turns at 2000 rpm Friction disc has coefficient of friction of .3. Determine torque and power that can be transmitted by this system.

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Example Problem 16-1: Torques and Forces on Clutches and Brakes (contd.)
Torque capacity:
(16-2)

Example Problem 16-2: Torques and Forces on Clutches and Brakes

Tf = f N

( ro + ri ) 2

12 in + 9 in Tf = .3 (120 lb) 2 Tf = 378 in-lb

For the short-shoe drum brake shown, determine the braking torque for the following dimensions: a = 4 in L = 20 in

Power:
(16-3)

D = 12 in f = .4 W = 100 lb:

Pf =

Tf n 63,000

Pf =

378 (2000) 63,000

Pf = 12 hp

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Example Problem 16-2: Torques and Forces on Clutches and Brakes (contd.)
Find moments to determine normal force:

Cone clutch
This becomes a bit complicated because of the cone angle In this case the frictional force is given by Tf = Ff rm= f N rm Fa Normal force, N = sin + f cos Fa = axial force = cone angle 20

Mp = WL a N Mp = 100 lb 20 in 4 in N
N = 500 lb Torque friction: Tf = f N D 2 12 in 2

Tf = .4 (500 lb)

Tf = 1200 in-lb This analysis assumes the lever arms stay approximately horizontal.
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Fig. 16.8 Cone clutch geometry

Cone clutch
Combining the above two equations we get

Tf =

f rm Fa sin + f cos

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Example Problem 16-3: Torques and Forces on Clutches and Brakes

Example Problem 16-3: Torques and Forces on Clutches and Brakes (contd.)
(16-5)

Tf =

f rm Fa sin + f cos

For the cone clutch shown, determine the torquetransmitting capacity based on the following parameters: Dmean = 12 inches Fa = 75 lb f = .35 = 20 Also solve if = 10 and compare the results.
For = 10:

Tf =

12 in .35 75 lb 2 sin 20 + .35 cos 20 Tf = 235 in-lb 12 in .35 75 lb 2 sin 10 + .35 cos 10

Tf =

Tf = 304 in-lb

The smaller angle creates a greater wedging force and, correspondingly, larger torque capacity.
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Example Problem 16-4: Torques and Forces on Clutches and Brakes

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Example Problem 16-4: Torques and Forces on Clutches and Brakes

First, find the rate of deceleration. Converting 60 mph to ft/sec:

truck has total weight of 40,000 lb and is traveling 60 mph. The brake design calls for it to be able to stop in 400 feet. Determine stopping force required. Determine stopping torque required if wheels are 36 inches in diameter. Determine torque per brake, assuming there are 10 sets of brakes. Assuming each brake is a disc brake with mean radius of 10 inches, determine normal brake force if25 f = .4.

60 mph

5280 ft hr = 88 ft/sec mile 3600 sec

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Example Problem 16-4: Torques and Forces on Clutches and Brakes (contd.)
Find the stopping rate: D = Va t D t = Va

Example Problem 16-4: Torques and Forces on Clutches and Brakes (contd.)
Find the torque, if the wheels are 36 inches in diameter: T = Fr T = 12,100 lb 36 in 2

t =

400 ft 88 ft/sec 2

T = 217,800 in-lb For each wheel: T = 21,780 in-lb Braking normal force:
(16-2)

t = 9 sec V = at a = V t

Tf = f N rm Tf N = f rm N = 21,780 in-lb .4 10 in

a =

88 ft/sec 9 sec

a = 9.8 ft/sec2 Find the stopping force: F = W a g

N = 5,450 lb
F = 40,000 lb 9.8 ft/sec2 32.2 ft/sec2 F = 12,100 lb

This is a significant normal force, especially for a disc brake system.

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Rotational Inertia and Brake Power

Inertia and frictional horsepower Energy from rotating torque Uf = F D Nt = Tf 2 Nt Uf = Frictional work D = effective diameter Nt = number of turns

Rotational Inertia and Brake Power

Power associated with stopping T n Uf Pf = f = 63,000 550 t Tf in-lb inn rpm t seconds

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Heat generated
Energy absorbed can be the potential energy or the kinetic energy Potential energy, PE = W (h1 h2)
W (V12 V22 ) Potential energy, KE = 2g

Temperature rise is c = specific heat

T =

Uf Wm c

= 101 ft-lb/lb/F for cast iron ft- lb/lb/ = 93 ft-lb/lb/F for steel ft- lb/lb/ = 15 ft-lb/lb/F for aluminum ft- lb/lb/

Wm = weight of brake system that can absorb the heat

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Example Problem 16-5: Rotational Inertia and Brake Power

Example Problem 16-5: Rotational Inertia and Brake Power

Converting 50 mph to ft/sec: hr 5280 ft = 73 ft/sec 3600 sec mile
(16-9)

3500-pound automobile is traveling 50 mph and decelerates on flat ground at a rate of 20 ft/sec2. Each of the four steel brake drums weighs 10 pounds. Assuming all heat is absorbed by the drums during this period, find energy absorbed, average frictional power, and temperature rise of drums.

50 mph

Kinetic energy to be absorbed: KE = WV2 2g

KE =

3500 lb (73 ft)2 2(32.2 ft/sec2) sec2

KE = 289,620 ft-lb (Energy gain U = KE lost.)

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Example Problem 16-5: Rotational Inertia and Brake Power (contd.)

Uf = W c T
(16-12)

Example Problem 16-5: Rotational Inertia and Brake Power (contd.)

Frictional power could then be found:
(16-7)

T = W c
289,620 ft-lb T = ft-lb 40 lb 93 lbF

Uf

f hp =

Uf KE = 550 t 550 t 289,620 550 (3.7)

T = 78
Finding the stopping time:

fhp =

f hp = 142
V = a t
t =

V
a

t =

73 ft/sec 20 ft/sec2

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t = 3.7 sec

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Automotive brake

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