‫الكلية التقنية اهلندسية‬ ‫وزارة التعليم العايل والبحث العلمي‬

‫قسم هندسة تقنيات ميكانيك القوى‬ ‫اجلامعة التقنية الشمالية‬

‫‪Engineering Technical College‬‬

‫‪MECHANICAL DESIGN‬‬
‫‪3rd YEAR‬‬
‫‪LECTURE 16 – CLUTCHES AND BRAKES‬‬

‫حممد مجال عيسى‬

‫ماجستري هندسة ميكانيك‬
 CLUTCHES

• Clutch is a machine member used to connect or disconnect a driving shaft to a

driven shaft Clutch

N1 driving shaft driven shaft N2

• Types of clutches
• Positive clutches
• Friction clutches
• Electromagnetic Clutches
 TYPES OF CLUTCHES

• Positive clutches
• Power transmission is achieved by means of interlocking of jaws or teeth.
• They can transmit large torque with no slip.

• Friction clutches
• Power transmission is achieved by means of
friction between contacting surfaces.

• Electromagnetic Clutches
• Power transmission is achieved by means
of the magnetic field.
• rapid response time, ease of control
SINGLE DISC OR PLATE CLUTCH
 DESIGN OF A DISC OR PLATE CLUTCH

• Uniform pressure.
• T = μ.W.R
3 3
2 r1 − r2
• R= 2 2
3
r1 − r2

• Uniform axial wear.

• T = μ.W.R
r1 + r2
• R= R = Mean radius of friction surfaces
2 T = Torque transmitted by the clutch
μ = Friction coefficient
W = Axial thrust force
 DESIGN OF A DISC OR PLATE CLUTCH

• n1 = Number of discs on
the driving shaft.
• n2 = Number of discs on
the driven shaft.
• Number of pairs of
contact surfaces,
• n = n1 + n2 – 1
• T = n.μ.W.R
• Uniform pressure.
3 3
2 r1 − r2
• R= 3 2 2
r1 − r2
• Uniform axial wear.
r1 + r2
• R= 2
 NOTES ON CLUTCHES

• For a single disc or plate clutch, normally both sides of the disc are effective. Therefore a single disc clutch has
two pairs of surfaces in contact (i.e. n = 2).
• Since the intensity of pressure is maximum at the inner radius (r2) of the friction or contact surface, therefore
• pmax = C / r2
W
• C=
2π (r1 – r2)
• Since the intensity of pressure is minimum at the outer radius (r1) of the friction or contact surface, therefore
• pmin = C / r1
• The average pressure ( pav) on the friction or contact surface is given by
Total force on friction surface W
• pav = =
Cross−sectional area of friction surface π (r12 – r22)
• The uniform pressure theory gives a higher friction torque than the uniform wear theory.
• In case of a new clutch, the intensity of pressure is approximately uniform, but in an old clutch, the uniform wear
theory is more approximate.
 EXAMPLE 1

• A plate clutch having a single driving plate with contact surfaces on each side is required to transmit
110 kW at 1250 r.p.m. The outer diameter of the contact surfaces is to be 300 mm. The coefficient of
friction is 0.4.
a) Assuming a uniform pressure of 0.17 N/mm2
• Determine the inner diameter of the friction surfaces.
b) Assuming the same dimensions and the same total axial thrust, determine the maximum torque that
can be transmitted and the maximum intensity of pressure when uniform wear conditions have been
reached.
• Solution:
• a) inner diameter d2
• T = n.μ.W.R
P × 60 110000 × 60
• 𝑇= = = 840 N.m
2πN 2 π 1250
• W = Pressure × Area = p × π [(r1)2 – (r2)2] = 0.17 × π [(150)2 – (r2)2]
• W = 0.534 × π [(150)2 – (r2)2]
 EXAMPLE 1

3 3 3 3 • pmax = C / r2
2 r1 − r2 2 150 − r2
• R= 3 2 2 = 2 W
3 2 • C=
r1 − r2 150 − r2 2π (r1 – r2)
• T = n.μ.W.R 9011
• C= = 19.122 N/mm
2π (150 – 75)
3 3
2 150 − r2 • pmax = 19.122 / 75
• 840(103) = 2 (0.4) × 0.534 × π [(150)2 – (r2)2] × 3 2
2 • pmax = 0.255 N/mm2
150 − r2
• 840(103) = 0.285 [(150)3 – (r2)3]
• (r2)3 = 425 × 103 r2 = 75 mm
• d2 = 150 mm
• b) Maximum Torque and max. intensity of pressure
• W = 0.534 × π [(150)2 – (r2)2] = 0.534 × π [(150)2 – (75)2] = 9011 N
• R = (150 + 75)/2 = 112.5 mm
• T = n.μ.W.R = 2 (0.4) × 9011 × 112.5 = 811(103) N.mm
 BRAKES

• The major function of brakes is to stop a moving member or to control its speed.
• The design of a brake depends upon the following factors:
1. The unit pressure between the braking surfaces.
2. The coefficient of friction between the braking surfaces.
3. The peripheral velocity of the brake drum.
4. The projected area of the friction surfaces.
5. The ability of the brake to dissipate heat equivalent to the energy being absorbed.
 ENERGY ABSORBED BY A BRAKE

• Kinetic energy of translation • Total energy

1 1 1
• Ek = m v2 • E = m v2 + I w2 + Wh
2 2 2
• Kinetic energy of rotation • work done
1 • Ew = E = Ft × π d N × t
• Ek = I w2
2 d
• Potential energy • T = Ft ×
2
• Ep = Wh
• T = Torque capacity of the brake
• W = Weight • Ft = Tangential braking force
• m = mass • d = Diameter of the brake drum
• v = the velocity • N1 = Speed of the brake drum before the brake is applied
• w = the angular velocity • N2 = Speed of the brake drum after the brake is applied
• h = the vertical distance • N = Mean speed of the brake drum = (N1+N2) / 2
• I = mass moment of inertia about its axis of rotation • t = the braking time
 THERMAL CONSIDERATIONS

• The energy absorbed by the brake is converted into heat, which increases the temperature at the
rubbing surfaces.
• Δ t = E / mc (Actual value is obtained by experiments)
• Δ t : temperature rise of the brake drum assembly (°C)
• E : total energy absorbed by the brake (J)
• m : mass of the brake drum assembly (kg)
• c : specific heat of the brake drum material (J/kg°C)
 DISK BRAKES

• A disk brake is similar to a plate clutch, except that one of the shafts is replaced by a fixed member.
• T = n.μ.W.R
• Uniform pressure.
3 3
2 r o − r i
• R= 2
3
ro 2 − ri
• Uniform axial wear.
ro + ri Rc / e 
• R=
2 0.0 1.0000
• W = average pressure / area of pad
0.1 9.833
1
• A=  (ro2 –ri2) 0.2 0.9693
2 R=e
• ro: Outer radius of pad 0.3 0.9572
• ri: Inner radius of pad 0.4 0.9467
•  : angular dimension of the pad 0.5 0.9375
 EXAMPLE 1

• Following data is given for a caliper disk brake with annular pad, for the front wheel of the
motorcycle:
• Torque capacity = 1500 N.m
• Outer radius of pad = 150 mm
• Inner radius of pad = 100 mm
• Coefficient of friction = 0.35
• Average pressure on pad = 2 MPa
• Number of pads = 2
• Calculate the angular dimension of the pad.
• Solution:

3 3 3 3
2 ro − ri 2 150 − 100
• R= 2 = 2 2 = 126.67 mm
3 3
ro 2 − ri 150 − 100
 EXAMPLE 1

• T = n.μ.W.R
• 1500 (123) = 2 (0.35) × W × 126.67
• W = 16,916.9 N
• W = average pressure / area of pad
1 1
• A =  (ro2 – ri2) =  (1502 – 752 )
2 2
1
• 16916.9 = 2 ×  (1502 – 752 )
2
•  = 1.3533 rad
•  = 77.54
INTERNAL EXPANDING DRUM
CLUTCHES AND BRAKES

Courtesy of Hillard Corporation, Elmira, New York

 CONE CLUTCHES AND BRAKES

• Due to the increased frictional area and the

wedging action of the parts, cone clutches
convey a larger torque than disk clutches with
the identical outside diameters and actuating
forces.
• Cone clutches are often used in low-speed
applications.
SHORT & LONG-SHOE DRUM BRAKES

If the angle of contact is small, 2 < 45°),

the shoe is relatively short (uniform pressure distribution)
 BAND BRAKES

• T1 / T2 = e
• TB = (T1 – T2) r

• T1 = σt × w × t
• w = Width of the band
• t = Thickness of the band
QUESTIONS?