Machine Design 2

Engr. Joebert S. Melendrez

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 Table of Contents

Module 4: Clutches 40
Introduction 40
Learning Objectives 40
Lesson 1. Disk or Plate Clutch Force Analysis 41
Assessment Task 4 49
Summary 51

Module 5: Cone Clutch 52

Introduction 52
Learning Objectives 52
Lesson 1.Cone Clutch Forces or Load Analysis 53
Assessment Task 5 58
Summary 60

Module 6: Sliding, Ball, and Roller Bearing 61

Introduction 61
Learning Objectives 61
Lesson 1. Ball, Sliding, and Roller Bearing Designation and Design 62
Assessment Task 6 67
Summary 68

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 MODULE 4
CLUTCHES

Introduction

Clutch is a machine member that is used to connect shafts so that the driven shaft will
rotate with the driving shaft, and to disconnect when needed. Clutch is a mechanical assembly
used to connect a driving member with a driven, collinear member. Jaw clutches are clutches
with jaws and teeth in the two elements interlock. Friction clutches are clutches in which the
driving force is transmitted by friction; the major types are: plate or disk clutch, cone clutch,
block clutch, and expanding ring clutch. Hydraulic clutches are clutches in which torque is
transmitted by a moving fluid. Electromagnetic clutches are clutches in which torque is
transmitted by means of a magnetic field (Francisco, 2014).

Learning Outcomes

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

1. Understand the different types of clutch

2. Solve different clutch problem
3. Design simple clutch machine
4. Understand different formula regarding clutch
5. Analyze equation regarding clutch

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Lesson 1. Disk or Plate Clutch Force Analysis (Francisco, 2014)

Brakes and Clutches Operation

• In the operation of a friction clutch during engagement, the initial condition is that the
driving member is moving and the driven member is at rest; in the final condition both
members are moving at the same speed.
• In the operation of a brake during braking, the initial condition is that one member,
such as the brake wheel or drum, is moving and the braking member is stationary; in
the final condition both members are at rest and having no relative motion.
Force Analysis of Disk or Plate Clutch
• In the design and analysis of clutches, two categories are being considered, namely:
new clutch is to be used or designed (uniform pressure theory or category); and old
clutch or clutch is already installed or used (uniform wear theory or category).
• Uniformly distributed pressure or constant pressure (Single Disk Clutch)
1. In this category, the surface is still uniform such that the clutch axial force is
distributed uniformly throughout its face.
2. Consider a single disk shown in Figure 4.1

p
d
𝑟𝑜

r
𝐹𝑎
𝑟𝑖

Figure 4.1 Uniform Pressure Disk Clutch

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Let,
dA = elementary surface area
𝐹𝑓 = frictional force
f = coefficient of friction, assumed as constant
normal force on dA = pdA = p2𝜋rdr
𝐹𝑎 = normal force or axial force
P = surface pressure
Elementary surface area, dA = 2𝜋rdr
Frictional force on dA = f(pdA) = 2𝜋rdrfp

1. Axial force or Normal force or Load

Do
𝑜 o 2
𝜋𝑝 r 2
𝐹𝑎 = ∫ 2𝜋𝑝rdr = 2𝜋p ∫ rdr = 2𝜋p [ ] = (𝐷𝑜2 − 𝐷𝑖2 )
𝑖 i 2 Di 4
2
2. Friction torque of the Disk
Do
o 3 2
𝜋𝑓𝑝 3r
𝑇𝑓 = 𝐹𝑡 (𝑟) = 2𝜋𝑓𝑝 ∫ r 2 dr = 2𝜋𝑓p [ ] = (𝐷𝑜 − 𝐷𝑖3 )
i 3 Di 2
2

From equation of axial force and friction torque

4𝜋𝑓𝐹𝑎 (𝐷𝑜2 − 𝐷𝑖2 ) (𝑓𝐹𝑎 )(𝐷𝑜3 − 𝐷𝑖3 ) 𝑓𝐹𝑎 2 𝑟𝑜3 − 𝑟𝑖3

𝑝= = = ( 2 )
12𝜋(𝐷𝑜2 − 𝐷𝑖2 ) 3(𝐷𝑜2 − 𝐷𝑖2 ) 3 𝑟𝑜 − 𝑟𝑜2
Where,
2 𝑟𝑜3 − 𝑟𝑖3
𝑟𝑚 = ( 2 ) = 𝑚𝑒𝑎𝑛 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑟𝑎𝑑𝑖𝑢𝑠 𝑓𝑜𝑟 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒
3 𝑟𝑜 − 𝑟𝑜2

𝑇𝑓 = 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑 𝑡𝑜𝑟𝑞𝑢𝑒 𝑖𝑛 𝑜𝑛𝑒 𝑝𝑎𝑖𝑟 𝑜𝑓 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑠𝑢𝑟𝑓𝑎𝑐𝑒𝑠 𝑖𝑛 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡

𝐷𝑜 = 𝑜𝑢𝑡𝑒𝑟 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
𝐷𝑖 = 𝑖𝑛𝑛𝑒𝑟 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟

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 𝑭𝒂
𝐷_𝑜 𝐷𝑖

Figure 4.2 Single Disk Clutch

Uniform Axial Wear Clutch (Single Disk Clutch) (Francisco, 2014)

• Due to usage, the clutch surface wears out; wearing greatest on the inner surface
and least on the outer surface of contact. Thus, maximum pressure is exerted on the
inner surface and minimum pressure on the outer surface.
• The mechanism of wear is the gradual tearing away by interlocking (friction) of
particles of the rubbing surfaces.
• The normal wear of the surface is proportional to the work of friction
• Based from the figure 4.3 below,
Let,
n = normal wear (perpendicular to the surface) n = kpr
k = constant of proportionality
• When the equilibrium condition is reached,
n = kpr = constant p =C/r

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 𝑘𝑝2 𝑟2 𝑘𝑝2 𝑟2

p
𝑟𝑜
𝑘𝑝1 𝑟1 𝑘𝑝1 𝑟1

𝐹𝑎
𝑟𝑖

Figure 4.3 Single disk clutch diagram

• For the axial load

𝐷𝑜 𝐷𝑜 𝐷𝑜
𝐷𝑜
2 2 𝐶 2
𝐹𝑎 = 2𝜋 ∫ 𝑝𝑟 𝑑𝑟 = 2𝜋 ∫ 𝑟 𝑑𝑟 = 2𝜋𝐶 ∫ 𝑑𝑟 = 2𝜋𝐶[𝑟]𝐷2𝑖
𝐷𝑖 𝐷𝑖 𝑟 𝐷𝑖
2
2 2 2

𝐷𝑜 𝐷𝑖
𝐹𝑎 = 2𝜋𝐶 ( − ) = 𝜋𝐶(𝐷𝑜 − 𝐷𝑖 )
2 2
• For the frictional torque

𝐷𝑜 𝐷𝑜 𝐷𝑜
2 2 𝐶 2
𝑇𝑓 = 2𝜋𝑓 ∫ 𝑝𝑟 2 𝑑𝑟 = 2𝜋𝑓 ∫ 𝑟 2 𝑑𝑟 = 2𝜋𝑓𝐶 ∫ 𝑟 𝑑𝑟
𝐷𝑖 𝐷𝑖 𝑟 𝐷𝑖
2 2 2

𝐷𝑜 2 𝐷𝑖 2 𝜋𝑓𝐶 2
𝑇𝑓 = 𝜋𝑓𝐶 [( ) − ( ) ] = (𝐷𝑜 − 𝐷𝑖2 )
2 2 4

Taking the value of C from the equation of Torque

𝐹𝑓 4𝑇𝑓
𝐶= =
𝜋(𝐷𝑜 − 𝐷𝑖 ) 𝜋𝑓(𝐷𝑜2 − 𝐷𝑖2 )

Then obtaining the value of the frictional torque,

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 𝐹𝑎 𝐷𝑜2 − 𝐷𝑖2 𝐹𝑎 (𝐷𝑜 − 𝐷𝑖 )(𝐷𝑜 + 𝐷𝑖 )
𝑇𝑓 = 𝑓 ( ) ( ) = 𝑓( )[ ]
4 𝐷𝑜 − 𝐷𝑖 4 𝐷𝑜 − 𝐷𝑖
𝐹 𝑟 +𝑟
𝑇𝑓 = 𝑓( 𝑎 )(𝐷𝑜 + 𝐷𝑖 ) = 𝑓𝐹𝑎 ( 𝑜 𝑖 )
4 2

Where,
𝑟𝑜 +𝑟𝑖
𝑟𝑚 = ( ) = mean friction radius for uniform wear
2

Multiple Disk Clutch

• Constant Uniform Pressure Disk Clutch, 𝑇𝑓 = 𝑛𝑓𝐹𝑎 𝑟𝑚 (new clutch lining)
Where,
2 𝑟𝑜3 − 𝑟𝑖3 1 𝐷𝑜3 − 𝐷𝑖3
𝑟𝑚 = ( 2 ) = [ ]
3 𝑟𝑜 − 𝑟𝑖2 3 𝐷𝑜2 − 𝐷𝑖2
n = number of pairs of mating friction surfaces in contact

• Uniform wear disk clutch, 𝑇𝑡 = 𝑛𝑓𝐹𝑎 𝑟𝑚 (worn clutch)

Where,
𝑟𝑜 + 𝑟𝑖
𝑟𝑚 =
2
n = number of pairs of mating surfaces in contact

Sample Problem
1. An engine of motor vehicle with a wheel diameter of 712 mm develops 50 kW at 2
000 rpm. The combined efficiency of the differential and transmission is 75% with an
overall speed reduction of 25 is to 1. Outside and inside diameters of the clutch are
300 mm and 240 mm, respectively. There are two pairs of mating surfaces with a
coefficient of friction of 0.30. using uniform wear theory,
Determine the following:
a) The axial force on the clutch, kN
b) The draw bar pull developed, in kN
c) The speed of travel of the vehicle, in kph
Given: A uniform wear disk clutch

𝐷𝑜 = 300 𝑚𝑚
𝐷𝑖 = 240 𝑚𝑚
𝑓 = 0.30
Required:

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 a) The axial force
b) The draw bar pull developed
c) The speed of travel of the vehicle

𝑭𝒂
𝐷_𝑜 𝐷𝑖

Figure 4.4 Single Clutch

Solution:
a) Determination of the axial force
30𝑃 30(50)
Solving for the transmitted torque, 𝑇 = = = 0.239 𝑘𝑁. 𝑚 = 239 𝑁. 𝑚
𝜋𝑛 𝜋(2000)

𝑟𝑜 +𝑟𝑖 300+240
Solving for the mean radius, 𝑟𝑚 = = = 135 𝑚𝑚 = 0.135 𝑚
2 2

𝑇 239
Solving for the axial load or force, 𝐹𝑎 = = = 2950.62 𝑚𝑚 =
𝑛𝑠 𝑓𝑟𝑚 2(0.30)(0.135)
2.951 𝑘𝑁
b) Determination of draw bar pull
Note: draw bar pull is the force required to move the vehicle

Solving for the power transmitted to the wheels, 𝑃𝑤 = 𝑒𝑓𝑓(𝑃) = 0.75(50) = 37.5 𝑘𝑊

𝑁 2000
Solving for the wheels rpm, 𝑁𝑤 = = = 80 𝑟𝑝𝑚
𝑆𝑅 25

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 30𝑃𝑤 30(37.5)
For the transmitted torque to the wheels, 𝑇𝑤 = = = 4.476 𝑘𝑁. 𝑚
𝜋𝑁𝑤 𝜋(80)

2𝑇𝑤 2(4.476)
Solving for the draw bar pull, 𝐹𝑤 = = = 12.573 𝑘𝑁
𝐷𝑤 0.712
Draw bar pull = 12.573

c) Determination of vehicle speed, in kph

𝑉 = 𝜋𝐷𝑤 𝑁𝑤 = 𝜋(0.712)(80) = 178.945 𝑚/ min = 10.74 𝑘𝑝ℎ

2. A disk clutch having an outside diameter of 32 cm and an inside diameter of 12.7 cm

is connected to an engine that turns at 750 rpm. The coefficient of friction is 0.6 while
the pressure between the friction surfaces is 2 kg/𝑐𝑚2 .
Determine the following:
a) The force on the clutch pedal necessary to disengage the clutch disk from the engine
b) The power transmitted by the engine.

Given: a disk clutch

𝐷𝑜 = 32 𝑐𝑚
𝑓 = 0.6
𝐷𝑖 = 12.7 𝑐𝑚
𝑘𝑔
𝑝=2 2
𝑐𝑚

Required:

a) The axial force

b) The power transmitted

Solution:
a) Determination of the axial force
Consider a uniform pressure clutch

𝜋 𝑘𝑔 𝜋
𝐹𝑎 = 𝑝𝐴𝑓 = 𝑝 ( ) (𝐷𝑜2 − 𝐷𝑖2 ) = (12 ) ( ) [(32 𝑐𝑚)2 − (12.7)2 ]
4 𝑐𝑚2 4
𝐹𝑎 = 1355.142 𝑘𝑔 = 13 289.33 𝑁 = 13.289 𝑘𝑁

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 b) Determination of the transmitted power

2 𝑟𝑜3 −𝑟𝑖3 2 (16)3 −(6.35)3

Solving for the mean friction radius, 𝑟𝑚 = ( ) = ( ) [(16)2 ] = 11.689 𝑐𝑚
3 𝑟𝑜2 −𝑟𝑖2 3 −(6.35)2

Solving for the transmitted torque, 𝑇𝑓 = 𝑓𝐹𝑎 𝑟𝑚 = 0.60(13.3)(0.11869) = 0.9471 𝑘𝑁. 𝑚

𝜋𝑛𝑇𝑓 𝜋(750)(0.9471)
Solving for the power transmitted, 𝑃 = = = 74.39 𝑘𝑊
30 30

3. A multi disk clutch consists of 10 steel discs and 9 bronze discs. The effective outside
and inside diameters are 20.32 cm and 15.24 cm, respectively. if the axial force 540 N
is applied and the shaft turns at 1200 rpm, find the Hp capacity. Assume coefficient of
friction of 0.27.

Given: a multi disc clutch

𝑛𝑠 = 18 =Number of pairs of mating surfaces
𝐷𝑖 = 15.24 cm
f = 0.27
𝐷𝑜 = 20.32 cm
N = 1200 rpm
𝐹𝑎 = 540 N

Required:
The Hp capacity of the clutch

Solution:

Solving for the mean friction radius, assuming a uniform pressure clutch,

2 𝑟𝑜3 − 𝑟𝑖3 2 (10.16)3 − (7.62)3

𝑟𝑚 = ( 2 ) = ( )[ ] = 8.95 𝑐𝑚
3 𝑟𝑜 − 𝑟𝑖2 3 (10.16)2 − (7.62)2

Solving for the transmitted torque,

𝑇𝑓 = 𝑛𝑠 𝑓𝐹𝑎 𝑟𝑚 = 18(0.27)(540)(0.0895) = 234.88𝑁. 𝑚 = 0.235 𝑘𝑁. 𝑚

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Solving, for the transmitted Hp,

𝜋𝑁𝑇𝑓 𝜋(1200)(0.235)
𝑃= = = 29.52 𝑘𝑊 = 39.57 𝐻𝑝
30 30

Assessment Task 4

Answer the problem with proper solution and clear diagram. Avoid erasure and
observe neatness.

1. A valve type clutch is use to drive a centrifugal pump. The clutch must transmit
175 Hp at 1900 rev/min. to the pump, which starts and stops 40 times per hour
throughout its 12 hr per day operating period. Compute the torque acting on the
clutch.
2. A disk clutch having the following value:
𝐷𝑜 = 32 𝑐𝑚, 𝐷𝑖 = 12.7𝑐𝑚, 𝑟𝑝𝑚 = 750. The coefficient of friction is 0.6 while the
pressure between the friction surfaces is 2 kg/𝑐𝑚2 . Compute the force on the
clutch pedal necessary to disengage the clutch disc from the engine.

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3. A plate clutch has a single pair of mating surface 30 cm outside diameter and
22.5 cm inside diameter. The maximum pressure was found to be 825 kPa
considering the coefficient of friction of 0.25. Find the power that can be handled
based on the drive that rotates 200 rpm considering that this clutch has been
already or this clutch is already installed.
4. A plate clutch has a single pair of mating surface 30 cm outside diameter and
22.5 cm inside diameter. The maximum pressure was found to be 825 kPa
considering the coefficient of friction of 0.25. Find the power that can be handled
based on the drive that rotates 200 rpm considering that this clutch is newly
installed.
5. A truck develops 33.5 hp at 1000 rpm. The clutch used to transmit the
aforementioned power is a single plate clutch with two pairs of contact surfaces.
If the coefficient of friction is to be 0.40 and the mean diameter of the disk if to
be 190 mm, and the average normal stress on the clutch lining is 120 kPa,
compute the axial force to engage the clutch based on uniform wear.

6. A truck develops 33.5 hp at 1000 rpm. The clutch used to transmit the
aforementioned power is a single plate clutch with two pairs of contact surfaces.
If the coefficient of friction is to be 0.40 and the mean diameter of the disk if to
be 190 mm, and the average normal stress on the clutch lining is 120 kPa,
compute the inside diameter.

7. A disc clutch has 6 pairs of contacting friction surfaces. An axial force of 130
lbs. acts on the clutch. The shaft peed is 490 rpm. How much horsepower can
the clutch transmit if the frictional radius is 2 inches and the coefficient of friction
is 0.37?

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 Summary

Clutch is a machine element for connection and disconnection of shafts in equipment

drives especially while running. The clutch system engages and disengages the engine from
the transmission, enabling the driver to start, stop, idle in neutral and shift gears (Francisco,
2014).

Reference

Francisco, J. R. (2014). Lecture book in Machine Design, 2nd floor JCSF Review Center
Building, Brgy. Halang, Calamba City.

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 MODULE 5
Cone Clutch

Introduction

Clutch is a machine member that is used to connect shafts so that the driven shaft will
rotate with the driving shaft, and to disconnect when needed. Clutch is a mechanical assembly
used to connect a driving member with a driven, collinear member. Jaw clutches are clutches
with jaws and teeth in the two elements interlock. Friction clutches are clutches in which the
driving force is transmitted by friction; the major types are: plate or disk clutch, cone clutch,
block clutch, and expanding ring clutch. Hydraulic clutches are clutches in which torque is
transmitted by a moving fluid. Electromagnetic clutches are clutches in which torque is
transmitted by means of a magnetic field (Francisco, 2014).

Learning Outcomes

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

1. Determine the force or load analysis of cone clutch

2. Solve various problems involving cone clutch.
3. Familiarize on different kind of formula of cone clutch
4. Understand different diagram, figures, and uses of cone clucth

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Lesson 1. Cone Clutch Forces or Load Analysis (Francisco, 2014)

𝐹𝑎

dA
𝜃 2𝜋𝑟𝑑𝑟
p

Figure 5.1 Cone Clutch Diagram

2𝜋𝑟𝑑𝑟
Let, elementary surface area, 𝑑𝐴 =
𝑠𝑖𝑛𝜃

𝑝(2𝜋𝑟𝑑𝑟)
Normal force on dA, 𝑑𝐹𝑛 =
𝑠𝑖𝑛𝜃

𝑝(2𝜋𝑟𝑑𝑟)
Frictional force on 𝑑𝐴, 𝑑𝐹𝑡 = 𝑓 [ ]
𝑠𝑖𝑛𝜃

𝐷𝑜 𝐷𝑜
• For the axial force, 𝐹𝑎 = ∫ 2
𝐷𝑖 𝑝(2𝜋𝑟𝑑𝑟) = 2𝜋 ∫ 2
𝐷𝑖 𝑝𝑟𝑑𝑟
2 2
𝐷𝑜 𝐷𝑜
𝐶 𝐶
Consider the uniform wear clutch, 𝑝 = ; 𝐹𝑎 = 2𝜋 ∫𝐷2𝑖 ( ) 𝑟𝑑𝑟 = 2𝜋𝐶 ∫𝐷2𝑖 𝑑𝑟 =
𝑟 𝑟
2 2
𝜋𝐶(𝐷𝑜 − 𝐷𝑖 )

𝑓𝑝2𝜋𝑟𝑑𝑟
• For the transmitted torque or frictional torque, 𝑑𝑇𝑓 = ( )𝑟
𝑠𝑖𝑛𝜃
𝐷𝑜 𝐷𝑜
2𝜋𝑓 2 2𝜋𝑓 2 𝐶 2 2𝜋𝑓𝐶 2
𝑇𝑓 = ∫ 𝑑𝑟 2 𝑑𝑟 = ∫ ( ) 𝑟 𝑑𝑟 = (𝐷 − 𝐷𝑖2 )
𝑠𝑖𝑛𝜃 𝐷𝑖 𝑠𝑖𝑛𝜃 𝐷𝑖 𝑟 𝑠𝑖𝑛𝜃 𝑜
2 2
• Taking the value of C from uniform wear clutch and frictional torque
𝐹𝑎 4𝑇𝑓 𝑠𝑖𝑛𝜃
𝐶= =
𝜋(𝐷𝑜 − 𝐷𝑖 ) 𝜋𝑓(𝐷𝑜2 − 𝐷𝑖2 )

𝑓𝐹𝑎 𝑓𝐹𝑎 𝑟𝑜+𝑟𝑖

Then solving for the torque, 𝑇𝑓 = (𝐷𝑜 + 𝐷𝑖 ) = ( )
4𝑠𝑖𝑛𝜃 𝑠𝑖𝑛𝜃 2

53
 2𝑇𝑓 𝑠𝑖𝑛𝜃
Also, the minimum required axial load under operation, 𝐹𝑎 =
𝑓(𝑟𝑜 −𝑟𝑖 )

𝑓𝐹𝑎 2 𝑟𝑜3 −𝑟𝑖3

• For uniform pressure cone clutch, 𝑇𝑓 = [ ( )]
𝑠𝑖𝑛𝜃 3 𝑟𝑜2 −𝑟𝑖2

𝑇𝑓 𝑠𝑖𝑛𝜃 3 𝑟𝑜3 − 𝑟𝑖3

𝐹𝑎 = [ ( 3 )]
𝑓 2 𝑟𝑜 − 𝑟𝑖3

• Force to engage the clutch

▪ Theoretical force required to engage clutch
𝐹𝑒 = 𝐹𝑛 (𝑠𝑖𝑛𝜃 + 𝑓𝑐𝑜𝑠𝜃)
▪ Actual experiments showed that 𝑓 𝑐𝑜𝑠𝜃 is only 25% effective
𝑓𝑐𝑜𝑠𝜃
𝐹𝑒 = 𝐹𝑛 (𝑠𝑖𝑛𝜃 + )
4

Example problem

1. A cone clutch has an angle of 10° and a coefficient of friction of 0.42. Find the axial force
required if the capacity of the clutch is 7.46 kW at 500 rpm. The mean diameter of the active
conical section is 300 mm.

Figure 5.2 Cone Clutch Diagram

Given: A cone clutch

f = 0.42 𝜃 = 10° P = 7.46 kW
N = 500 rpm 𝑟𝑚 = 300 mm

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Required:
Find the axial force required

Solution:
Solving the transmitted torque,
30𝑃 30(7.46)
𝑇𝑓 = = = 0.1425 𝑘𝑁. 𝑚 = 142.5 𝑁. 𝑚
𝜋𝑁 𝜋(500)

𝑇𝑓 0.1425
Solving for the frictional force, 𝐹𝑓 = = = 0.9498 𝑘𝑁
𝑟𝑚 0.15
𝐹𝑓 949.84
Solving for the normal force on friction surface, 𝐹𝑛 = = = 2261.52 𝑁
𝑓 0.42
Solving for the axial force, 𝐹𝑎 = 𝐹𝑛 𝑠𝑖𝑛𝜃 = 2261.52 𝑠𝑖𝑛10° = 392.71𝑁

2. A cone clutch has a cone angle of 12.5° and a mean diameter of 50.8 cm. If the clutch is
to transmit 11.9 kW at 900 rpm and the coefficient of friction is 0.30, what axial spring force
is required? Calculate on the basis of uniform wear.
𝐹𝑛

𝐹𝑎

Figure 5.3 Cone Clutch Diagram

Given: A cone clutch

f = 0.30 𝜃 = 12.5° P = 11.19 kW N = 900 rpm
𝑟𝑚 = 50.8 cm

Required:
The axial force

55
Solution:
• Determination of the minimum required axial force or load under operation
30𝑃 30(11.19)
Solving for the transmitted torque, 𝑇𝑓 = = = 0.1187 𝑘𝑁. 𝑚
𝜋𝑁 𝜋(900)

𝐹𝑎
From the equation of torque in terms of load, 𝑇𝑓 = 𝐹𝑓 𝑟𝑚 = 𝑓𝐹𝑛 𝑟𝑚 = 𝑓 ( )𝑟
𝑠𝑖𝑛𝜃 𝑚

𝑇𝑓 𝑠𝑖𝑛𝜃 (0.1187)𝑠𝑖𝑛12.5°
Then, solving for the axial load, 𝐹𝑎 = =
𝑓𝑟𝑚 0.30(0.254)

𝐹𝑎 = 0.3372 𝑘𝑁 = 337.3 𝑁 → Minimum required axial load under operation

• Determination of axial load required to engage clutch

Consider the figure below, to compute for the axial load required to engage,

𝐹𝑛

𝜃
𝜃

𝐹′
𝐹𝑒

Figure 5.4 Cone Clutch Diagram

Summation Forces, ∑ 𝐹𝑛 = 0;

𝐹𝑒 = 𝐹𝑛 𝑠𝑖𝑛𝜃 + 𝐹 ′ 𝑐𝑜𝑠𝜃

𝐹𝑒 = 𝐹𝑛 𝑠𝑖𝑛𝜃 + 𝑓𝐹𝑐𝑜𝑠𝜃 = 𝐹𝑛 (𝑠𝑖𝑛𝜃 + 𝑓𝑐𝑜𝑠𝜃)

𝑇𝑓
Where, 𝐹𝑛 = (𝑠𝑖𝑛𝜃 + 𝑓𝑐𝑜𝑠𝜃)
𝑓𝑟𝑚

56
 0.1187
𝐹𝑒 = (𝑠𝑖𝑛12.5° + 0.3𝑐𝑜𝑠12.5°) = 0.3934 𝑘𝑁
0.30(0.254)

3. The outside and inside diameters of a cone clutch are 25.4 cm and 20.32 cm,
respectively, and the coefficient of friction is 0.30. The power capacity is 10 Hp at 1 000 rpm,
and the allowable pressure is 55.4 kPa. Find the face width if the design is based on uniform
pressure.
Given: A cone clutch
f = 0.30 P = 10 Hp N = 1 000 rpm 𝐷𝑜 = 25.4 cm 𝐷𝑖 = 20.32cm

𝐹𝑛

𝐹𝑎

Figure 5.5 Cone Clutch Diagram

Required: the cone face width

Solution:
Solving for the 𝑟𝑚 ,

25.4 3 20.32 3
2 𝑟𝑜3 − 𝑟𝑖3 2 ( ) − ( )
𝑟𝑚 = ( ) = ( )[ 2 2 2 ] = 11.48
3 𝑟𝑜2 − 𝑟𝑖2 3 25.4 20.32 2
( ) −( )
2 2

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 30𝑃 30(10)(0.746)
Solving for the torque, 𝑇 = = = 0.0712 𝑘𝑁. 𝑚
𝜋𝑁 𝜋(1000)

Solving for the face width, considering the equation of torque,

2 𝑟𝑜3 − 𝑅𝑖3
𝑇 = 𝑓𝐹𝑛 𝑟𝑚 = 𝑓𝑝(𝜋𝐷𝑚 )𝑏 = 𝑓[𝑝(𝜋𝐷𝑚 )𝑏] [ ( 2 )]
3 𝑟𝑜 − 𝑟𝑖2

𝑇 𝑇 71.2(1000)(1000)
𝑏= = 2 = = 51.98𝑚𝑚 = 2.05𝑖𝑛𝑐ℎ𝑒
𝑓𝑝(𝜋𝐷𝑚 )𝑟𝑚 2𝜋𝑓𝑝𝑟𝑚 2𝜋(0.3)(55140)(114.8)2

Assessment Task 5

Answer the following problem with proper solution and complete diagram.
Avoid erasure.
1. How much torque can a cone transmit if the angle of conical elements is 10
degrees, the mean diameter of the conical clutch sections is 200 mm and an axial
force of 650 N is applied? Note the coefficient of friction between the clutch
elements is 0.54.

58
2. An Industrial engine developing 34 hp at 1350 rpm is fitted with a cone clutch
built into the flywheel. The cone has a face angle of 12.8 degrees and a maximum
diameter of 16 inches. The coefficient of friction is 0.2. The normal pressure on
the clutch face is not to exceed 14 psi. Determine the face width required.
3. A sports utility vehicle production company have considered using in one of its
designs a multi disc clutch consisting of 11 steel discs and 10 bronze discs, with
effective outside and inside diameter of 220 mm and 160 mm, respectively. If the
shafts turns at 1600 rpm and an axial force of 750 Newtons are applied, find the
horse power capacity, considering a coefficient of friction of 0.28.

4. Determine the power capacity of a cone clutch under uniform pressure and
assuming the following conditions: major diameter = 250 mm; minor diameter =
200 mm; length of conical elements in contact = 125 mm; rotational speed = 870
rpm; coefficient of friction = 0.30; and allowable pressure = 70 kPa

5. How much torque can a cone torque transmit, if the angle of conical elements
is 10 degrees, the mean diameter of the conical clutch sections is 180 mm and
an axial force of 550 N is applied? Note: the coefficient of friction between the
clutch elements is 0.54.

6. A cone clutch has cone elements at an angle of 11.1°. The mean diameter of
the conical friction sections is 14 inches and the coefficient of friction is 0.38.
Find the axial force needed to engage the clutch considering that the clutch
transmits 20 hp at a speed of 1080 rpm.

7. Passenger jeep route Sta.cruz to Calamba has a soft surface cone clutch that
can handle 215 x 103 N.mm of torque at 1200 rpm. The large diameter of the clutch
is 350 mm and the included angle is 20 degrees. The width of the face is 85 mm.
using a coefficient of friction of 0.26, determine the axial force required to engaged
the clutch.

59
 Summary

In actual design the application of empirical formula is a must using standard came
from different codes which is approved by different government agency is a big help in
innovation of existing design and also for the safety of the users. This code of standard should
always apply in every machine designed.

Reference

Francisco, Jose R. (2014), Lecture book in Machine Design, 2 nd floor JCSF Review Center
Building, Brgy. Halang, Calamba City.

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 MODULE 6
Sliding, Ball, and Roller Bearing

Introduction

Bearing is a machine member that supports another part that rotates, slides, or
oscillates in or on it. Rolling element bearing is a bearing where surfaces are non conformed
and motion is primarily rolling; it is composed of rolling elements interposed between outer
and inner rings (Francisco, 2014).

Learning Outcomes

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

1. Determine the different kinds of bearing used in machine design

2. Determine the different application of bearing
3. Analyze different diagram and figures regarding bearing design
4. Solve different bearing problem and calculation
5. Solve problems provided at the example on this module and assessment task

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Lesson 1. Ball, Sliding, and Roller Bearing Designation and
Design (Francisco 2014)

SHAFT

Extra
light 100
series

Light 200
Heavy Extra
series
400 heavy 500
series series
Medium
300 series
Figure 6.1 Ball and Roller Bearing Designation

Two types of bearing elements (Francisco, 2014)

1. Sliding element (sliding bearing) – type of bearing where essentially sliding friction
exists.
2. Rolling element
a) Ball bearing – type of rolling element bearing which uses spherical balls as rolling
element.
b) Roller Bearing - type of rolling element bearing which uses cylindrical rollers as
rolling elements.

Sliding Bearings
𝐶𝑑 = diametral clearance
𝐶𝑑 = D – d

62
𝐶𝑟 = radial clearance
𝐷−𝑑 𝐶𝑑
𝐶𝑟 = R – r = =
2 2

𝐹
P = unit of loading or bearing pressure =
𝐿𝐷
e = eccentricity = radial distance between the center of bearing and the
𝐶𝑑
e= - ℎ𝑜 = 𝐶𝑟 - ℎ𝑜
2

F 𝐶𝑑

D
d

JOURNAL
SHAFT

e
ℎ𝑜
BEARING

Figure 6.2 Sliding Bearing Diagram

Where,
D = diameter (bore) of the bearing
d = diameter of the journal
L = axial length of the journal inside the bearing
F = radial load
ℎ𝑜 = film thickness = lubricants space

𝜇𝑁
Bearing Modulus =
𝑝
Where:
𝜇 = viscosity in reyns
𝑙𝑏.𝑠𝑒𝑐
1 reyn = 1
𝑖𝑛2

63
 𝑑𝑦𝑛𝑒.𝑠𝑒𝑐
1 poise = 1
𝑐𝑚2
N = speed in rps
P = unit loading in psi

Frictional torque in bearings

𝑇𝑏 = 𝐹𝑓𝑏 𝐷

Where:
𝑇𝑏 = frictional torque
F = radial load
𝑓𝑏 = coefficient of friction
D = bearing diameter

Frictional Power

𝑃𝑓 = 2𝜋𝑇𝑁 = 𝑓𝑊𝑉

Where:
f = coefficient of friction
N = rotative speed (rpm or rps)
W = weight or load (N or lb.)
V = velocity (m/s or ft/s)
𝑃𝑓 = frictional power (kW or Hp)

Bearing Capacity Based on Stresses

• For Ball Bearings
𝐾1 𝑛𝐷 2
𝐹𝑟 =
5

• For Roller Bearings

𝐾2 𝑛𝐿𝐷
𝐹𝑟 =
5
Where,
𝐹𝑟 = total radial load, lbs
n = number of balls or rollers

64
D = ball diameter or roller diameter, inch
L = length of rollers, inch
𝐾1 = 550 for unhardened steel
= 700 for hardened carbon steel
= 1 000 for hardened alloy steel on flat races
= 1 500 for hardened carbon steel
= 2 000 for hardened alloy steel on groove races
𝐾2 = 7 000 for hardened carbon steel
= 10 000 for hardened alloy steel

Example problem
1. The main bearings of a one cylinder steam engine are 152 mm diameter and 280 mm long
and support a load of 4 400 kg. The bearings are well ventilated and are heavy in construction.
The coefficient of friction in bearings is 0.017 and crankshaft rotates at 450 rpm. Bearing
diametral clearance is 0.152. Determine the unit loading per bearing.

Solution:
4400
Load per bearing = = 2200 𝑘𝑔
2

𝐹 2200(2.205)
P = unit loading = = 280 152 = 73.5 𝑝𝑠𝑖
𝐿𝐷 (25.4)(25.4)

Note: 2.205 conversion of kg to lbs and 25.4 mm to inches

2. The main bearings of a one cylinder steam engine are 152 mm diameter and 280 mm long
and support a load of 4 400 kg. The bearings are well ventilated and are heavy in construction.
The coefficient of friction in bearings is 0.017 and crankshaft rotates at 450 rpm. Bearing
diametral clearance is 0.152. Determine the friction loss per bearing.

Solution:

𝑓𝐹𝐷 2200(0.00981)(0.017)(0.152)
T = frictional torque = = = 0.027884 𝑘𝑁. 𝑚
2 2
Friction loss = 2𝜋𝑇𝑁 = 2𝜋(0.027884)(450/60) = 1.314 kW

65
3. The weight of each wheel of a motor driven travelling crane is 6 000 lb. the wheels are 2 ft.
in diameter and are carried on journals 4 inch in diameter and 8 inch long. The coefficient of
rolling friction is 0.02 and sliding friction 0.5. Determine the horsepower of the motor required
to drive a four wheel crane travelling 500 ft/minute.

Solution:
𝑃𝑓 = frictional power = 𝑓FV
0.02(24000)(500)
Hp for Rolling friction = = 7.27 𝐻𝑝
33000
33 000 is a conversion of power

0.5(24000)(8.333)
Hp for Sliding friction = = 10.3 𝐻𝑝
33000

Hp total = 7.27 Hp + 3.03 Hp = 10.3 Hp

66
 Assessment Task 6

Answer the following problem with proper solution and complete diagram.
Avoid erasure.

1. A 38 mm shaft uses a sleeve bearing that sustains a load of 4 500 N. Compute

the length of the bearing and the L/D ratio considering that bearing pressure is 1.7
Mpa.
2. A bearing carries a load of 4 550 kN. The shaft diameter is 1 200 mm, the
coefficient of friction is 0.02, and the shaft speed is 420 rpm. Compute the power
lost in the bearing.
3. A horizontal shaft of 1.2 inch in diameter rotates at 500 rpm in a sleeve bearing.
The coefficient of friction is 0.18. If the reaction between the shaft and the bearing
is 900 lbs, compute the horsepower lost in the bearing.
4. The cutting machine has a sleeve bearing with an outside diameter of 1.54 inch
and a length of 2 inch the wall thickness is 5/16 inch. The bearing is subjected to
a radial load of 450 lb. find the bearing pressure.
5 and 6. Draw the following:
Ball Bearing
Tapered Roller Bearing
Roller Bearing
Each figure should have a complete parts and designation; draw the following in
clean white short bond paper.

67
 Summary

The purpose of bearing lubrications:

• To provide a low friction film between the rolling elements and the races of the bearing
and at points of contact with cages, guiding surfaces, retainers and so on.
• To protect the bearing component from corrosion
• To help dissipate heat from the bearing unit
• To carry heat from the bearing unit
• To help dispel contaminants and moisture from the bearing

Reference

Francisco, Jose R. (2014), Lecture book in Machine Design , 2nd floor JCSF Review Center
Building, Brgy. Halang, Calamba City.

68