MACHAKOS UNIVERSITY

SCHOOL OF ENGINEERING

DEPARTMENT OF MECHANICAL AND MANUFACTURING ENGINEERING

PROGRAMME:

BSc. MECHANICAL ENGINEERING

UNIT:

EMM301: MECHANICS OF MACHINES 1

LECTURER:

MR JOHNSON NGUGI

MAY, 2021

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 LECTURE SIX

Lecture overview

A friction clutch is used to transmit power between two shafts. There are two types of friction
clutches, namely, flat clutches and conical clutches. In this lesson, we shall discuss the
mechanics of power transmission using flat friction clutches. Specifically, we shall consider
the mechanics of power transmission in flat plate clutches using the uniform pressure theory.
We shall derive the relevant equations and look at worked examples.

This lecture covers:

(i) Lecture objectives

(ii) Lecture notes: The Mechanics of friction clutches 1
(iii) Summary of the lecture
(iv) Suggestions for further reading

Lecture Objectives

At the end of this lecture, students should be able to:

(i) Distinguish between flat and conical friction clutches.

(ii) Derive expressions for the thrust and torque acting on the frictional surfaces of a
plate clutch using the uniform pressure theory
(iii) Evaluate engineering problems involving the application of flat friction clutches.

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 3. FRICTION CLUTCHES
3.1. Introduction

A clutch is normally used to transmit power from one shaft to another co-axial shaft. The main
advantage in using a clutch, as opposed to coupling, for instance, is that the clutch may be readily
disengaged, when power is not required to be transmitted, and re-engaged when power is required
to be transmitted. With friction clutches, another advantage is that gradual engagement of the
clutch is possible, thus allowing for the smooth transfer of power and avoiding sudden impact
torques.

There are two types of friction clutches namely, flat and conical friction clutches. However, only
flat clutches shall be considered in this course since they have largely replaced conical friction
clutches in industrial applications for the following reasons:

(i) The large effective frictional area that can be installed in a compact unit, through the
use of multiple discs
(ii) More effective heat dissipation surfaces
(iii) Favourable pressure distribution.
(iv) Freedom from centrifugal forces

In flat plate clutches, the clutch plates are usually surfaced with special heat-resistant ceramic
material that has a high coefficient of friction when used with pressure plates made of ferrous
metal.

3.2. Mechanics of a Flat Plate Clutch

A plate clutch assembly like the one shown in Fig. 1 is made up of 3 main parts: a plate clutch, a
flywheel, and a pressure plate.

The plate clutch has an annular geometry and is lined on both sides with a ceramic material (usually
Ferodo) with a high coefficient of friction. The flywheel is usually bolted to the crankshaft (driving
shaft). It is also lined with friction material on the side which makes contact with the clutch. The
pressure plate is used to maintain contact between the flywheel and the plate clutch. The diaphragm

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spring is designed in such a way that when a driver steps on the clutch pedal, it breaks the contact
between the plate clutch and the flywheel.

Fig. 1: Plate clutch assembly

Consider two friction surfaces (e.g. clutch plate and flywheel), maintained in contact by an axial
thrust 𝑊 (from the pressure plate), as shown in Fig. 2.

Fig. 2: Two friction surfaces in contact

Now consider an infinitesimally small ring at a distance 𝑟 from the centre of the clutch plate with
a thickness 𝑑𝑟.

If 𝑟1 𝑎𝑛𝑑 𝑟2 are the internal and external radius of the clutch plate, 𝑝 the intensity of the pressure
between the two surfaces, 𝐹𝑟 the friction between the two surfaces and 𝑇 the torque transmitted
between the two surfaces, the normal force, 𝑑𝑊 acting on the elemental ring is given by:

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𝑑𝑊 = 𝑝 × 2𝜋𝑟. 𝑑𝑟 … … … … … … … … . . (𝑖)

The frictional force acting tangentially at 𝑟 is given by:

𝐹𝑟 = 𝜇𝑑𝑊

𝐹𝑟 = 𝜇𝑝 × 2𝜋𝑟𝑑𝑟 … … … … … … … … … (𝑖𝑖)

Therefore, the frictional torque acting on the ring is given by:

𝑑𝑇 = 𝐹𝑟 × 𝑟

𝑑𝑇 = 𝜇𝑝 × 2𝜋𝑟 2 𝑑𝑟 … … … … … … … . . (𝑖𝑖𝑖)

Therefore, torque transmitted is given by:

𝑟
𝑇 = 2𝜋𝜇 ∫𝑟 1 𝑝𝑟 2 𝑑𝑟 … … … … … … … … (𝑖𝑣)
2

Two theories can be used to characterize the mechanics of a clutch plate depending on whether it
is new or worn out, namely, uniform pressure theory and uniform wear theory.

(a) Uniform Pressure Theory

This theory assumes that the pressure between the two friction surfaces is uniform across the
contact area and best describes the mechanics of a plate clutch when it is new.

With that in mind, equation (iv) becomes,

𝑟
𝑇 = 2𝜋𝜇𝑝 ∫𝑟 1 𝑟 2 𝑑𝑟 … … … … … … … … (𝑣)
2

Integrating,

𝑟2
𝑟3
𝑇 = 2𝜋𝜇𝑝 { 3 } … … … … … … … … … . (𝑣𝑖)
𝑟1

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Simplifying,

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𝑇 = 3 𝜋𝜇𝑝(𝑟23 − 𝑟13 ) … … … … … … … … (𝑣𝑖𝑖)

When the pressure is uniformly distributed over the entire area of the friction surface,

𝑊
𝑝 = 𝜋(𝑟 2−𝑟 2) … … … … … … … … … … … (𝑣𝑖𝑖𝑖)
1 2

Substituting the value of 𝑝 in equation (viii) into equation (vii),

2 𝑟23 −𝑟13
𝑇 = 𝜇𝑊 { } … … … … … … … … … … (𝑖𝑥)
3 𝑟22 −𝑟12

In cases where there are more than one friction surfaces, equation (ix) becomes,

2 𝑟23 −𝑟13
𝑇 = 𝑛𝜇𝑊 { } … … … … … … … … … … (𝑥)
3 𝑟22 −𝑟12

Where 𝑛 is the number of pairs of friction surfaces in contact. A single plate clutch has two pairs
of friction surfaces. One pair is formed between the clutch and the flywheel and the other between
the clutch and the pressure plate.

Worked Example 1

The external and internal diameters of a plate clutch are 240 mm and 120 mm respectively.
Assuming uniform pressure, find the total spring load pressing the plates together to transmit
25 𝑘𝑊 at 1575 𝑟𝑒𝑣/𝑚𝑖𝑛. Take 𝜇 = 0.3.

For uniform pressure,

2 𝑟 3 −𝑟 3
𝑇 = 3 𝜇𝑊 𝑟12−𝑟22
1 2

𝑝𝑜𝑤𝑒𝑟×60 25×103 ×60

𝑇= = = 151.6 𝑁𝑚
2𝜋𝑁 2𝜋×1575

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 2 0.123 −0.063
151.6 = 3 × 0.3 × 𝑊 (0.122−0.062)

𝑊 = 5414.3 𝑁

Worked Example 2

The following data is provided for a multiplayer clutch.

Number of pairs of contact surfaces: 5

Speed: 2000 rpm
Outer radius: 75 mm
Inner radius: 40 mm
Coefficient of friction: 0.25
Axial force, W: 600 N

Calculate the maximum power that the clutch can transmit without slipping based on constant
pressure theory

Solution:

For uniform pressure theory (for a multiplayer clutch system),

2 𝑟13 −𝑟23
𝑇 = 𝜇𝑛𝑊
3 𝑟12 −𝑟22

2 0.0753 −0.043
𝑇 = 3 × 0.25 × 5 × 600 × {0.0752−0.042}

𝑇 = 43.125 𝑁𝑚

2𝜋𝑁 2𝜋×2000
𝑃𝑜𝑤𝑒𝑟 = 𝑇𝜔 = 𝑇 × = 43.125 × = 9032 𝑊𝑎𝑡𝑡𝑠
60 60

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Summary

In this lesson, we discussed the mechanics of power transmission via flat friction clutches by
considering application of uniform pressure on the clutch surfaces.

Further Reading

1. Khurmi, R.S. & Gupta, J.K. (2015). Theory of Machines (5th Ed.). New Delhi, IN: S.
Chand & Company.
2. Uicker, J., Pennock, G. & Shigley, J. (2010). Theory of Machines and Mechanism (4th
Ed.). Oxford, UK: Oxford University Press.
3. Hannah, J. & Stephens. R.C. (1962). Mechanics of Machines: Elementary Theory and
Examples, London, UK: Edward Arnold (classic book).