II. Brake & Clutch - CH 2 Analysis

Analysis of Break & Clutch
MS3116 – Element Mesin II ‹#›

Representation
Brakes or Clutch
  angular velocity
1 2 I  inertia
Flywheel
I2
I1
T  torque T i ,i T o ,o

  angular displacement
I ,
Figure 1
Performance Analysis
 The actuating force

 The torque transmitted
 The energy loss
 The temperature rise

Various Types of Devices

Rim types with internal expanding shoes
Rim type with external contracting shoes
Band types
Disk or axial types
Cone types
Miscellaneous types

Statics General procedures of

analysis steps.
1. Estimate or determine the
distribution of pressure
on the frictional surfaces.
2. Find a relation between
the maximum pressure
F
and the pressure at any
point.
3. Apply the conditions of
fN static equilibrium to find
N
the actuating force, the
Figure 2 torque, and the support
reactions.
Step 1.
Shoes is short  assume that pressure is uniform
Step 2.
From step 1  p  pa , pa  maximum pressure
Step 3.
Since the pressure is uniformly distributed, the normal
forces is given by
N  pa A  pa  (w 1  w 2 ) (a)
Taking the moment about point A, gives
M A  Fb  Nb  fNa  0 (b)
Substituting pa A for N and solving the previous equation

for the actuating force, we get
pa A(b  fa ) (c)
F 
b
Taking a summation of forces in the horizontal and
vertical directions gives the hinge-pin reactions:
 Fx  0  R x  fp a (w 1  w 2 )
(d)
 Fy  0  R y  p a (w 1  w 2 )  F
This completes the analysis of the problem.

 The preceding analysis is very useful when the

dimensions of the clutch or brake are known and the
characteristics of the friction material are specified.
 In design, we are interested more in synthesis than
in analysis; that is, our purpose is to select a set of
dimensions to obtain the best brake or clutch within
the limitations of the frictional material we have
specified.
 Note that the quantity (b – f a)/b in equation (c) is
always less than unity. This effect is called self-
energizing, because friction is reducing the
necessary actuating force.
 Certain critical value of the coefficient of friction, f can

cause the term (b – fa)/b to become zero. This called the
condition of self-locking. It’s the designer’s responsibility
to select values for the dimension a and b, to ensure that
self-locking will never occur unless it is specifically desired.
 Term fail-safe and dead-man are often encountered in
studying the operation of brakes and clutch.
Fail-safe means that if any element should fail to perform
its function, then no accident will occur in machine.
Dead-man refers to the locomotive-control mechanism
which cause the engine to come to a stop if the operator
should suffer a blackout or die at the controls.
Internal Expanding Rim Clutches & Brakes

Internal-shoe rim clutch
as shown in the figure
consist of 3 elements:
• the mating frictional
surface,
• the means of
transmitting the torque
to and from the
surfaces,
Figure 3 • the actuating
mechanism.
Depending upon the operating mechanism, such

clutches are classified as:
• expanding-ring 
• centrifugal, 

• magnetic, Read the utilization
• hydraulic, field of each type!

• pneumatic
In braking system, the internal-shoe or drum

brake is used mostly for automotive applications.
Force Analysis Let us consider the unit

pressure p acting upon an
element of area of the
frictional material located
at an angle  from the
hinge A.
We designate the
maximum pressure by pa
located at the angle a
from the hinge pin.
In this case, the uniform distribution of
pressure is not valid anymore!!!
Figure 4
Step 1
Make the assumption that the pressure at any point is
proportional to the vertical distance from the hinge
pin. This vertical distance is proportional to sin.
Step 2
From the step 1, the relation between the pressure is
p pa From eq. (1), p will be a

 (a) maximum when  = 90o, or if the
sin  sin a toe angle 2 is less then 90o, then
p will be a maximum at the toe.
sin
or p  pa (1) When  = 0, eq. (1) shows that
sina the pressure is zero.
Step 3
At the angle  from the hinge pin, there acts a differential
normal force dN whose magnitude is.
dN  pbr d (b)
Where b is the face width of the friction material.
Substituting the value of the pressure, eq. (1), we find
pa br sin  d
dN  (c)
sin a
The normal force, dN and other forces act on the friction
material can be decomposed into horizontal and vertical
component, as shown on the figure.
Step 3 (continued)
The actuating force F can be found by using the condition
that the summation of the moments about the hinge pin is
zero. 2
fp a br
M f   fdN r  a cos     sin  r  a cos  d (2)
sin a 1
2
p a bra
M N   dN a sin     sin 2
d (3)
sin a  1
The actuating force F must balance these two moments:

MN  Mf
F  (4)
c
Step 3 (continued)
If we make MN = Mf , self-locking is obtained, and no
actuating force is required.
To obtain self-energizing condition, the dimension a in
Figure must be such that
MN  Mf (5)
The torque T applied to the drum by the brake shoe is

the sum of the frictional forces fdN times the radius of
the drum:
fp a br 2 2
fp a br 2 cos 1  cos  2 
T   fr dN   sin d  (6)
sin a 1
sin a
Step 3 (continued)
The hinge pin reactions are found by taking a summation
of the horizontal and vertical forces, thus we have
R x   dN cos    fdN sin   F x
p a br (d)
 A  fB   F x
sin a
R y   dN sin    fdN cos   F y

p a br (e)
 B  fA   F y
sin a
where
2 2
A   sin  cos  d   sin   B   sin  d   2  sin 2  
2
2 2 2
1  1
2 1 4 1
1 1

Step 3 (continued)
The direction of the frictional forces is reversed if the
rotation is reversed. Thus, for counterclockwise rotation of
drum, the actuating force become
MN  Mf
F  (7)
c
Since both moments have the same sense, the self-
energizing effect is lost and also self-locking.
Also, for counterclockwise rotation the signs of frictional
terms in the equilibrium for the pin reactions change, and
equation (d) and (e) become:

Step 3 (continued)
R x   dN cos    fdN sin   F x



p a br
A  fB   F x (f) 
sin a  For
 counterclockwise
R y   dN sin    fdN cos   F y  rotation
p a br 
 B  fA   F y (g) 
sin a

The following assumption are implied by the preceding analysis:

1. The pressure at any point on the shoe is assumed to be proportional
to distance from the hinge pin, being zero at the heel.
2. The effect of centrifugal force has been neglected. In the case of
brakes, the shoes are not rotating, and no centrifugal force exists. In
clutch design, the effect of this force must be considered in writing
the equations of static equilibrium.
3. The shoe is assumed to be rigid. Since this cannot be true, some
deflection will occur, depending upon the load, pressure, and stiffness
of the shoe. The resulting pressure distribution may be different from
that which has been assumed.
4. The entire analysis has been based upon a coefficient of friction which
does not vary with pressure. Actually, the coefficient may vary with a
number of conditions including temperature, wear, and environment.

Read example 16-1:

The brake shown in Figure is 300
mm in diameter and is actuated y y
by a mechanism that exerts the
same force F on each shoe. The
shoe are identical and have a
face width of 32 mm. The lining
is a molded asbestos having a
coefficient of friction of 0.32 and
a pressure limitation of 1000 kPa.
a) Determine the actuating force F.
b) Find the braking capacity.
c) Calculate the hinge-pin x
x
reactions.
Figure 5
External Contracting Rim Clutches & Brakes

The patented clutch-brake of
Figure has external contracting
friction elements, but the
actuating mechanism is
pneumatic.
The mechanism can be classified as:
1. Solenoids
2. Levers, linkages, or toggle devices
3. Linkages with spring loading
4. Hydraulics and pneumatic devices
Figure 6
Force Analysis
The notation for external
contracting shoes is shown
in Figure 7.
The moments of friction and
normal forces about the
hinge pin are the same as
for the internal expanding
shoes.
Equations (2) and (3) apply
and repeated here for
convenience:
Figure 7
2
fp a br
M f   fdN r  a cos     sin  r  a cos  d (2)
sin a 1
2
p a bra
M N   dN a sin     sin 2
d (3)
sin a  1
Both equation give positive value for clockwise moments

when used for external contracting shoes. The actuating
force must be large enough to balance both moments:
MN  Mf
F  (11)
c
The horizontal and vertical reactions at the hinge pin are:

R x   dN cos    fdN sin   F x (12a)
p a br
 A  fB   F x
sin a
R y   fdN cos    dN sin   F y

p a br (12b)
 fA  B   F y
sin a
where
2 2
A   sin  cos  d   sin   B   sin  d   2  sin 2  
2
2 2 2
1  1
2 1 4 1
1 1

If the rotation is counterclockwise, the sign of the frictional

term in each equation is reversed. Thus equation for
actuating force becomes
MN  Mf
F  (13)
c
And self-energization exist for counterclockwise rotation. The
horizontal and vertical reaction are found to be
pa br
Rx  A  fB   F x (14a)
sin a
pa br
Ry  fA  B   Fy (14b)
sina
• When external contracting designs are used as clutches,

the effect of centrifugal force is to decrease the normal
force. Thus, as the speed increases, a larger value of the
actuating force F is required.
• A special case arise when the pivot is symmetrically located
and also placed so that the moment of the friction forces
about the pivot is zero. The geometry of such a brake will
be similar to that of figure 8.
• To get a pressure-distribution relation, we assume that the
lining wears so as always to retain its cylindrical shape.
This means that the wear x in Figure 8 (b) is constant
regardless of the angle . Thus the radial wear of the shoe
is r = x cos .

r
x
wear
Figure 8

• If, on any elementary area of the shoe, we assume that

energy or frictional loss is proportional to the radial
pressure, and if we also assume that the wear is directly
related to the frictional loss, by direct analogy, we have.
p  pa cos  (a)
and p is maximum at   0o
• The normal force, from Fig 8.a we find that
dN  pbr d (b)
or
dN  p a br cos d (c)
• The distance a center of drum to pivot is to be chosen such

that the moment of the frictional forces Mf is zero.
Symmetry means that 1 = 2, and so
2
M f  2  (f dN )(a cos   r )  0 (d)
0
• Substituting Eq. (c) gives

2
2f p a b r  (a cos   r cos  )d  0
2
0
• From which we obtain
Rework this result at
4r sin2
a (15) home by your own way!
22  sin 22
• The moment about the pin is zero (due to chosen pivot)

and the pin reactions are
2
pa b r
R x  2  dN cos   22  sin 22  (16)
0
2
2
pa b r f (17)
R y  2  fdN cos   22  sin 22 
0
2
where  fdN sin  0 and  dN sin   0

• Note, that Rx = -N and Ry = - f N as might be expected for
the particular choice of the dimension a; and the torque is
T  af N (18)

Band-Type Clutches and Brakes

Application, mostly:
• Power excavators
• Hoisting machinery
• Others
Broderson IC-80-1D Carry Deck

• Engine: Continental TM27, 4 cyl., 165
C.I.D., 64 hp at governed speed.
• Transmission: Borg Warner, 72T/T18,
Reversing Gearbox and Manual Shift Three
Speed Gearbox.
• Brakes: Service - 4-wheel drum type

brakes, Parking - Band Type
Mounted on Transmission

Element d, in
equilibrium under
the action of the
forces, so summing
the forces in
P1  P2 Why? vertical direction,
we have
Figure 9 Note:
for small angles,
(P  dP ) sin d
2
 P sin d
2
 dN  0 (a)
d d
or *) sin 
2 2
dN  Pd (b) *)dP  d  0
Summing the forces in horizontal direction gives

(P  dP ) cos d2  P cos d2  f dN  0 (c)
or
dP  f dN  0 (d)
Substituting the value of dN from Eq. (b) in (d) and
integrating gives
P1 
dP P1
P P  f 0 d  ln P2  f 
2
and
P1
 ef (19)
P2
The torque may be obtained from the equation

T  1
2
P1  P2  D (20)
The normal force dN acting on element is
dN  p b r d (e)
Substitution of dN from Eq. (b) gives
P d  p b r d
Therefore P 2P
p  (21)
br bD
The maximum pressure will occur at the toe with the value
2P1
p  (22)
bD
Frictional-Contact Axial Clutches

• Mating frictional members
are moved in a direction
parallel to shaft
• Most application: automotive

Figure 10 Figure 11
Single-plate disk clutch, Multiple-plate disk clutch,
application: car application: motor cycle
 Advantages of the disk clutch:

 Freedom from centrifugal effects
 Large frictional area which can be installed in
small space
 More effective heat-dissipation surfaces
 Favorable pressure distribution
 Two methods:
 Uniform wear
 Uniform pressure

 Uniform wear
After initial wear has
taken place and the disks
have worn down to the
point where uniform wear
becomes possible, the
greatest pressure must
occur at r = d/2 in order
for wear to be uniform.
Denoting the maximum Figure 12
pressure by pa, we can d d
then write pr  pa or p  pa
2 2r
Referring to Fig. 12, we have an element of area of radius r

and thickness d/2. The area of this element is 2r dr , so
that the normal force acting upon this element is dF = 2pr
dr . Thus, the total normal force become
D /2 D /2
p a d (23)
F   2pr dr  pad d dr  D  d 
d 2 2
2
The torque is found by integrating the product of the
frictional force and the radius
D /2 D /2
fp a d
T   2fpr dr  fpad
2
 rdr  8
D 2
d 2
 (24)
d 2 d 2
Ff
T  D  d  (25)
4
 Uniform Pressure
When uniform pressure can be assumed over the area of
the disk, the actuating force F is simply the product of
the pressure and the area pa 2
F 2
4
D d  (26)
As before, the torque is found by integrating the product
of the frictional force and the radius:
fpa 3
D  d 3  (27)
D/2
T  2fpa  r dr 
2
d 2
24
Ff D 3  d 3 
T (28)
3 D2  d 2
Note:
All equations are for single pair of mating surface. This value must be
therefore be multiplied by the number of pairs of surfaces in contact:
Difference characteristic of
uniform pressure and uniform wear
Figure 13
Disk Brakes
• There is no fundamental
difference between a disk
clutch and a disk brake.
• The analysis of preceding
section applies to disk brakes
too.
• Disk brake has no self-
energization, and hence is not
so susceptible to changes in
the coefficient of friction.

• Fig. 14 shows a floating

caliper disk brake.
• The caliper support a single
floating piston actuated by
hydraulic pressure.
• The action is like a screw
clamp, with the piston
replacing the function of the
screw.
• The floating action
compensates for wear and
ensures a fairly constant
pressure over the area of the
friction pads.
Figure 14

Cone Clutch and Brakes

• Consist of a cup and a cone.
• Cone angle and the diameter and
face width of the cone are the
important geometric design
parameters.
• If the cone angle is too small, say,
less than about 8o, then the force
required to disengage the clutch
may be quite large.
• Wedging effect lessens rapidly
when larger cone angles are used.
• A good compromise can usually be
found between 10o – 15o.
Operating force and torque

transmitted can be found
using Fig. 15.
Uniform Wear
The pressure relation is the
same as for the axial clutch
d Figure 15
p  pa (a)
2r
The element area dA of radius r and width dr sin is

dA  (2r dr ) sin  (b)
As shown in Fig. 15, the operating force will be the integral of

the axial component of the differential force pdA. Thus
D 2
 d  2r dr 
F   pdA sin   d 2  a 2r  sin 
p (sin  )

D 2
p a d (29)
F  p a d d dr  D  d 
2
2
which is the same result as in Eq. (23).

The differential friction force is f p dA, and the torque is
D 2
 d  2r dr 
T   rfp dA   (rf ) p a  
d 2  2r  sin  
D 2
fp a fp a d
T 
sin  d 2r dr 
8 sin 
D 2
 d 2
 (30)

Note that Eq. (24) is a special case of Eq. (30), with  = 90o.
Using Eq. (29), the torque can also be written
Ff
T  D  d  (31)
4 sin 
Uniform Pressure
Using p = pa, the actuating force and torque are found to be
D 2
 2r dr  p a 2
F   p a dA sin    p a   sin   
D d 2  (32)
d 2  sin   4
D 2
 2r dr  fp a
T   rfpa dA   
 a  sin   12 sin 
rfp    D 3
 d 3
 (33)
d 2
Ff
D3 d 3
T  (34)
3 sin  D 2  d 2
Energy Conservations
• In the case of braking action, the kinetic energy must be
absorbed by the brake.
• This energy appears in the brake in the form of heat.
• For the clutching action, slipping must occur in the clutch
until the driven parts have the same speed as the driver.
• Kinetic energy is absorbed during slippage of either a clutch
or brake, and this energy appears as heat.
• The capacity of a clutch or a brake is limited by two factors:
characteristic of material and ability of clutch/brake to
dissipate heat.
• If the heat generated faster than it is dissipated, we the
temperature-rise problem.
• To study what happens during a simple clutching/braking

operation, let see the Fig. 16 .
I 1 and I 2 have
Brakes or Clutch
initial angular
velocity of 1 and 2 .
1 2 During the clutch
operation, both angular
I2
I1 velocity change and
Figure 16 eventually become equal.
• Assumption:
 The two shafts are rigid
 The torque is constant. f
Equation of motion for inertia 1 can be written:

I 11  T (a) where  is angular accelerati on
(b) and T is clutch torque.
I 22  T
The instantaneous angular velocities for both inertia can
be determined as follows
 T (c) T (d)
1  t  1 
2  t  2
I1 I2
The difference in velocities (relative velocity), is
2 
      T t    T t  
1 I1 1   I2 2 
  I1  I 2 
  1  2  T   t (35)
 I 1I 2 
The clutching operation is completed at the instant when

1 and 2 become equal. Let the time required for entire
operation be t1. Then the Eq. (35) gives the time as
I 1I 2 (1  2 ) (36)
t1 
T (I 1  I 2 )
Using Eq. (35), the rate of energy-dissipation during the
clucthing operation is
 (I 1  I 2 ) 
u  T   T (1  2 )  T
 t  (e)
 I 1I 2 
This equation shows that the energy-dissipation rate is
greatest at the start of clutching, when t = 0.
The total energy dissipated during the clutching operation

or braking cycle is obtained by ontegrating Eq. (e) from t
= 0 to t = t1. The result is found to be
t1 t1
  (I 1  I 2 )  
E   udt  T  (1  2 )  T  t dt
0 0   I 1I 2  
I 1I 2 (1  2 ) 2
E  (37)
2(I 1  I 2 )
Notes:
 This is energy is absorbed by clutch or brake.
 In SI unit, the inertias are expressed in kg-m, the
angular velocities are in rad/s, and the energy
dissipated is expressed in joules.
Temperature Rise
The temperature rise of the clutch or brake assembly can
be approximated by the classic expression.
T  temperatur e rise, o C
E
T  (38) C  specific heat;
C m (use 500 J/kg for steel or cast iron)
m  mass of clutch or brake parts, kg
An object heated to a temperature T1 cools to an ambient

temperature Ta according to the exponential relation.
AU
t
T i  T a  T1  T a e

mC (39)
T i  instantane ous temperatur e rise at time t , o C
where A  heat - transfer area, m 2
U  surface coefficien t, joules m 2  s  oC 
Figure 17
Friction Material
 A brake or clutch friction material should have the
following characteristics to a degree which is dependent
upon the severity of the service:
1. A High and uniform coefficient of friction
2. Imperviousness to environmental conditions, such as
moisture
3. The ability to withstand high temperature, together
with good heat conductivity
4. Good resiliency

Table of several common friction material

Material Fabrication Field of Application
Woven-cotton As a fabric belt which impregnated with Mostly in heavy machinery; usually in
resin and polymerized rolls up to 50 ft length. Thickess frm
lining 1/8 in to 1 in; width up to 12 in.
Woven-asbestos Similar to cotton lining and may contain Widely used as a brake material in
metal particles. Not as flexible as cottong heavy machinery. Comes in smaller
lining lining. range of sizes.
Molded-asbestos Contain asbestos fiber and friction modifiers; Principal use is in drum brakes.
thermoset polymer is used, with heat, to
lining form a rigid/semi0rigid molding.
Molded-asbestos Similar to molded lining but have no Used both for clutches and brakes.
flexibility.
pads
Sintered-metal pads Made of a mixture of copper and/or iron Pads are used in both brakes and
particles with friction modifiers; molded clutches for heavy-duty applications.
under high pressure and the heated to a
high temperature to fuse the material.
Cermet pads Similar to the sintered-metal pads and have Pads are used in both brakes and
a substantial ceramic content. clutches.
See table 16-1 and 16-2 for properties of friction material

Miscellaneous Clutches and Coupling

 Square-jaw clutch as shown in Fig. 18 (a) in one form of
positive-contact clutch. These clutches have the following
characteristics:
1. They do not slip
2. No heat is generated
3. They cannot be engaged at high speeds
4. Sometimes they cannot be engaged when both shafts are at rest
5. Engagement at any speed is accompanied by shock.
 The greatest differences among the various types of positive
clutches are connected with the design of the jaws (ractched-
shaped, spriral-shaped, gear-tooth-shaped).
 Although positive clutches are not used to the extent of the
frictional-contact types, they do have important applications
where synchronous operation is required.
Square-jaw Overload-release clutch

Figure 18
 Devices such as linear drives or motor-operated

screwdrivers must run to a definite limit and then come to
a stop.
 An overload-release type of clutch required for theses
application. Fig. 18 (b) is a schematic drawing illustrating
the principle of the operation of such clutch.
 This clutches are usually spring-loaded so as to release at
a predetermined torque.
 The clicking sound which is heard when the overload
point is reached is considered to be a desible signal.
 Both fatigue and shock must be considered in obtaining
the stress and deflections of the various portions of
postive clutches. In addition, wear must generally be
considered.
 An overrunning clutch or
coupling permits the driven
member of a machine to
“freewheel” or “overrun”
because the driver is stopped or
because another source of
power increases the speed of
the driven mechanism.
 The driving action is obtained by wedging the rollers

between the sleeve and the cam flats.
 There are many varieties of overrunning clutches available,
and they are built in capacities up to hundreds HP.
 Since no slippage is involved, the only power loss is that due
to bearing friction and windage.

Plain shaft coupling Light duty toothed coupling
BOST-FLEX through-bore coupling Three-jaw coupling


Flywheel
 A flywheel is used to smooth out variations in the speed of a
shaft caused by torque fluctuations.
 Piston compressors, punch presses, rock crusher, etc. all have
time-varying loads.
 The prime mover (ex.: internal combustion engine) introduce
torque oscillations to the transmission shaft.
 Other systems may have both smooth torque sources and
smooth loads such as an electrical generator driven by a steam
turbine, have no need for a flywheel.
 If the source of driving torque or the load torque have a
fluctuating nature, then a flywheel is usually called for.
 A flywheel is an energy storage device. It absorbs and stores
kinetic energy when speeded up and returns energy to the
system when needed by slowing its rotational speed.
 The equation of motion for Flywh

the flywheel represented eel
in Fig. 19 is T i ,i T o ,o
M  T i (i , i )  T o (o , o )  I   0

I ,
or T  torque;   angular displacement
I   T i (i , i )  T o (o , o ) (a) Figure 19
Note:
 Ti is considered positive and To negative.
 Both Ti and To may depend for their values on the angular displacement as
well as their angular velocities.
 In many case (ex. induction motor), its characteristic depends upon only the
speed of the motor. Generally, motor manufacturers publish the torque-speed
characteristics of their various motors.
 When the input and output torque functions are given, Eq. (a)
can be solved for the motion of the flywheel using well-known
techniques for solving linear and non-linear differential
equation. We can dispense with this here by assuming a rigid
shaft, giving i =  = o . Thus, Eq. (a) becomes
I   T i ( , i )  T o ( , o ) (b)
 When the two torque functions are known and the starting
values of the displacement  and velocity  are given, Eq. (b)
can be solved.
 Here we are not really interested in the instantaneous values of
these terms at all. Primary we want to know the overall
performance of the flywheel (what should its moment of
inertia?, How do we match the power sources to the load?,
what are the resulting performance?, etc.)
 To gain insight into the problem, a hypothetical situation is

diagrammed in Fig. 20.
Energy absorbed
by flywheel
T , 2 3
Ti  Energy released
1 4 back to system
Ui
3 4
1 2 Uo 
To
1 cycle
Figure 20
 The work input to the flywheel is the area of the rectangle
between 1 and 2 , or.
U i  Ti (2  1 ) (c)
 The work output of the flywheel is the area of the rectangle

between 3 and 4 , or.
U o  To ( 4  3 ) (d)
 Three conditions possible (assume: no friction losses)

If U o  U i  4  1 ; load uses more energy than has been delivered to the flywheel
If U o  U i  4  1 ; the gains and the losses are equal
If U o  U i  4  1 ; load uses less energy than has been delivered to the flywheel
 These relation can also be written in terms of kinetic energy.

At  = 1 the flywheel has a velocity of 1 rad/s, and so its
kinetic energy is
E 1  12 I 12 (e)
 At  = 2 the velocity is 2 rad/s, and so its kinetic energy is

E 2  12 I 22 (e)
 Thus the change in kinetic energy is

E  E 2  E 1  12 I 22  12  (40)
 Note:
 Many of the torque displacement functions encountered on
practical engineering situations are so complicated that they
must be integrated by approximate methods.
 One simplest integration routine is Simpson’s rule; this
approximation can be handled on any computer and is short
enough to use on the smallest programmable calculators.
Read and rework example 16-2.
Example 1.
The crankshaft of a punch
press rotates at 60 rpm,
causing holes to be punched in
a steel part at the rate of 60
punches per minute. The
crankshaft torque requirement
is shown in Fig. 21. The press
is driven (through suitable
speed reducers) by a 1200-rpm
motor.
Neglecting any “flywheel
effect”, what motor power is
required to accommodate the Figure 21
peak crankshaft torque?
Assumption:
1. Friction losses are negligible
2. No energy is stored as rotational kinetic energy (no flywheel)
3. The motor delivers maximum torque continuously
Solution:
1. Neglecting friction losses  motor power = crankshaft power
out, and the 20 : 1 speed reduction (1200 rpm/60 rpm) is
associated with a 20 : 1 torque increase.
Hence, the motor torque is 10 kN·m/20 = 500 N·m.
2. Motor delivers the torque continuously. The work capacity
corresponding to 1 revolution of the shaft is 2 x 500 N·m =
1000 J.
3. In 1 second, the motor shaft turns 20 revolutions (1200 rpm), the
work capacity is 20 kJ. This is equivalent to 20 kW or 62.8 kW
or 84.2 hp.
Example 2.
For the punch press in
example 1 determine the
motor power capacity
required if use is made a
flywheel. The energy
required for the press is
represented by the area
under the actual crank
torque versus the crank
angle curve of Fig. 22, which
is 2 kN·m or 6283 Joules.
Figure 22
Assumption: Friction losses are negligible

Solution:
1. Fig. 22 shows that average torque requirement during the actual
punch stroke is 6 kN and that the punch stroke lasts for /3 rad.
(The energy involved is this area under the curve is 2 kN·m or
6283 J.). By using the flywheel that permits the motor to deliver a
constant torque over the entire 2 rad, we can reduce the torque
requirement to 1 kN·m. This is shown in Fig. 22 as “uniform torque
supplying equal energy”.
2. Since, at the same shaft speed, motor torque and motor power are
proporsional, the 10:1 reduction in motor torque corresponds to a
like reduction in power rating required.
Hence, the motor power required is 62.8 kW/10 = 6.28 KW or equal
to 8.4 hp.

Example 3.
Continuing with the previous
problem, we choose to design a
flywheel that rotates at 1/3
motor speed and that limits
motor speed fluctuation to the
range of 900 rpm to 1200 rpm.
The flywheel is to be made of
steel and have the geometric
proportions as shown in Fig. 23.
Figure 23
To simplify the calculation, assume that the inertia contributed by the
hub and arms is negligible. Determine the required flywheel polar
moment of inertia, I, and the diameter, d.

Assumption/decisions:
1. The flywheel rotates at 1/3 motor speed.
2. Motor speed fluctuation is limited to 900 to 1200 rpm.
3. The flywheel is made of steel.
4. Geometric proportions for the flywheel are shown in Fig. 23.
5. The inertia contributed by the hub and arms is negligible.
6. Friction losses are negligible.
Solution:
1. Fig. 22 shows that during the actual punch stroke, energy provided
by the motor is represented by an approximate rectangle 1 kN·m x
/3 rad. Thus, the motor provides 1000 x /3 = 1047 J of the total
of 6283 J required. The flywheel must provide the remaining (6283
– 1047) = 5236 J.
2. The flywheel inertia must be such that

5236  12 I max
2
 min
2
 (*)
max  1
3
1200 rpm  40
rad
 13.33
rad
3 s s
30 rad rad
min  13 900 rpm   10
3 s s
Substituti on these values to the Eq. (*) gives
5236  12 I 13.33  2  10 2   I  13.80 kg  m2
2. The moment of inertia for a hollow cylinder is

I  
32
d 4
o 
 d i4  L  
13.80  
32
d 4

 (0.8d ) 4 0.2d 7700
From wich we find d  688 mm
Comment:
If the inertia contributed by the hub and arms is included in the analysis,
we would find that a smaller d is required.

II. Brake & Clutch - CH 2 Analysis

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II. Brake & Clutch - CH 2 Analysis

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Analysis of Break & Clutch

MS3116 – Element Mesin II ‹#›

T  torque T i ,i T o ,o

 The actuating force

MS3116 – Element Mesin II ‹#›

Various Types of Devices

MS3116 – Element Mesin II ‹#›

Statics General procedures of

Substituting pa A for N and solving the previous equation

This completes the analysis of the problem.

MS3116 – Element Mesin II ‹#›

 The preceding analysis is very useful when the

 Certain critical value of the coefficient of friction, f can

Internal Expanding Rim Clutches & Brakes

Depending upon the operating mechanism, such

In braking system, the internal-shoe or drum

Force Analysis Let us consider the unit

p pa From eq. (1), p will be a

The actuating force F must balance these two moments:

The torque T applied to the drum by the brake shoe is

R y   dN sin    fdN cos   F y

MS3116 – Element Mesin II ‹#›

MS3116 – Element Mesin II ‹#›

R x   dN cos    fdN sin   F x

MS3116 – Element Mesin II ‹#›

The following assumption are implied by the preceding analysis:

MS3116 – Element Mesin II ‹#›

Read example 16-1:

External Contracting Rim Clutches & Brakes

Both equation give positive value for clockwise moments

The horizontal and vertical reactions at the hinge pin are:

R y   fdN cos    dN sin   F y

MS3116 – Element Mesin II ‹#›

If the rotation is counterclockwise, the sign of the frictional

• When external contracting designs are used as clutches,

MS3116 – Element Mesin II ‹#›

MS3116 – Element Mesin II ‹#›

• If, on any elementary area of the shoe, we assume that

• The distance a center of drum to pivot is to be chosen such

• Substituting Eq. (c) gives

• The moment about the pin is zero (due to chosen pivot)

where  fdN sin  0 and  dN sin   0

MS3116 – Element Mesin II ‹#›

Band-Type Clutches and Brakes

Broderson IC-80-1D Carry Deck

• Brakes: Service - 4-wheel drum type

MS3116 – Element Mesin II ‹#›

Summing the forces in horizontal direction gives

The torque may be obtained from the equation

Frictional-Contact Axial Clutches

MS3116 – Element Mesin II ‹#›

 Advantages of the disk clutch:

MS3116 – Element Mesin II ‹#›

Referring to Fig. 12, we have an element of area of radius r

MS3116 – Element Mesin II ‹#›

• Fig. 14 shows a floating

MS3116 – Element Mesin II ‹#›

Cone Clutch and Brakes

Operating force and torque

The element area dA of radius r and width dr sin is

As shown in Fig. 15, the operating force will be the integral of

which is the same result as in Eq. (23).

MS3116 – Element Mesin II ‹#›