Machine Design - Design of Clutches

Brown Hills College of Engineering & Technology
Machine Design - 1
UNIT 7______________________________________________ D e s i g n o f C l u t c h e s
Various types of clutches in use, Torque transmitting capacity, Design of friction clutches Disc,
Multidisc, Cone & Centrifugal.
Introduction
A Clutch is a machine member used to connect the driving shaft to a driven shaft, so that the
driven shaft may be started or stopped at will, without stopping the driving shaft. A clutch thus
provides an interruptible connection between two rotating shafts.
Clutches allow a high inertia load to be stated with a small power.
A popularly known application of clutch is in automotive vehicles where it is used to connect
the engine and the gear box. Here the clutch enables to crank and start the engine
disengaging the transmission Disengage the transmission and change the gear to alter the
torque on the wheels. Clutches are also used extensively in production machinery of all types
The driven shaft should be disengaged from the driving shaft. The engagement and
disengagement of the shafts is obtained by means of a clutch which is operated by a lever.
Function of clutches:
1. To permit engagement or disengagement of a gear when the vehicle in stationary and
the engine is running.
2. To transmit the power to the wheels smoothly without shock to the transmission
system while selting the vehicle motion.
3. To permit the engine of the gears when the vehicle is in motion without the gear
wheel.
The amount of torque a clutch can transmit depends on the co-efficient of friction between
the friction facings and their mating surfaces, the mean radius of the facings, the number of
facings in contact, and the total spring force.
Increasing the diameter of a clutch increases its torque capacity, as does increasing the
spring force. Two or more clutch plates can be used to form a multi-plate clutch, increasing
the number of facings, and torque capacity. They are useful where a reduction in diameter
is advantageous or where increasing the spring strength is undesirable.
Main part of the clutch:
1. Driving member
2. Driver member
3. Operating member
Sachin Chaturvedi Lecturer in Department of Mechanical Engineering
Notes also available at www.sachinchaturvedi.wordpress.com
For your assistance write an email on email ID. E-mail: sachin_techno@yahoo.co.in
Machine Design - 1
1. Deriving member: it consists of a flywheel mounted on the engine crankshaft.

2. Deriver member: it consists of a disc or plate, called clutch plate.
3. Operating member: it consists of a foot pedal, linkages, bearing, release lever, spring etc.
Chart for the types of clutches:

Clutch
Positive
Clutch
Diaphram
Clutch
Hydraulic
Clutch
Electromagnetic
Clutch
Vaccum
Clutch
Over Running
Clutch
Gradual
Eengagement
Clutch
Dog or Spline
Clutch
Friction Clutch
Cone Clutch
Internal
Clutch
External
Clutch
Disc or Plate Clutch
Single Plate
Clutch
Wet Clutch
Fluid Clutch or Fluid Flywheel
Centrifugal Clutch
Semi-Centrifugal
Clutch
Multiple Plate
Clutch
Dry Clutch
Types of Clutches: The two main types of clutches commonly used in engineering practice:
1. Positive Clutches.
2. Friction Clutches.
1. Positive Clutches: The positive clutches are used when a positive drive is required. The
simplest type of a positive clutch is a jaw clutch. The jaw clutch permits one shaft to drive
another through a direct contact of interlocking jaws.
It consists of two halves, one of which is permanently fastened to the driving shaft and the
other half of the clutch is movable and it is free to slide axially on the driven shaft, but it is
prevented from turning relatively to its shaft.
The jaws of the clutch may be of square and spiral type as shown in Fig. (a, b).
Machine Design - 1
(a) A square jaw type is used where engagement and disengagement in motion and under
load is not necessary. This type of clutch will transmit power in either direction of
rotation.
(b) The spiral jaws may be left-hand or right-hand, because power transmitted by them is in
one direction only. This type of clutch is occasionally used where the clutch must be
engaged and disengaged while in motion.
The use of jaw clutches are frequently applied to sprocket wheels, gears and pulleys. In
such a case, the non-sliding part is made integral with the hub .
2. Friction Clutches: The friction force is used to start the driven shaft from rest and
gradually brings it up to the proper speed without excessive slipping of the friction surfaces.
In automobiles, friction clutch is used to connect the engine to the drive shaft. In operating
such a clutch, care should be taken so that the friction surfaces engage easily and
gradually bring the driven shaft up to proper speed. The proper alignment of the bearing
must be maintained and it should be located as close to the clutch as possible.
Types of Friction Clutches: There are three types of friction clutches as following:
1. Disc or Plate Clutches (Single Disc or Multiple Disc Clutches)
2. Cone Clutches
3. Centrifugal Clutches
Friction between two surfaces depends upon the following are:
1. Area of the surfaces
2. Pressure applied
3. Coefficient of friction of the surface material
Types of friction material are:
1. Leather: Coefficient of friction , = 0.3
2. Fabric: Coefficient of friction , = 0.4

Machine Design - 1
Torque Transmitting Capacity (TTC): A friction disk of a single plate clutch is shown in figure:
Let,
D and d = outer and inner diameter of friction disk
p = Intensity of axial pressure
F = Total operating force
T = Torque transmitted by the clutch
r = Mean radius of the friction face, and
= Coefficient of friction.
Consider an elementary ring of radius r and radial thickness dr as shown in Fig.
We know that for this ring:
Fig: c
Area = 2 r.dr
Axial force = Pressure Area = p 2 r.dr
Frictional force = F= .p 2 r.dr
Frictional torque = .p 2 r.dr r = 2 .p r2 dr
There are two criteria to obtain torque capacity as follows:
1. When there is a uniform pressure (Uniform Pressure Theory).
2. When there is a uniform wear (Uniform Wear Theory).
1. Uniform Pressure Theory: In case of new clutches employing a number of springs, the
pressure can be assumed to be uniformly distributed over the entire surface area of the friction
disk or plate as shown in Fig. (c), then the total operating fore is,
(1)

Machine Design - 1
(2)
Divide eq. (2) by eq. (1) we get;
(3)
The above equations have been derived for a single pair of mating surfaces. When there is a
number of friction surfaces in contact, as in the case of the multi-disk clutch, eq. (3) should be
multiplied by the number of pairs of contacting surface to obtain the resultant torque
transmitting capacity.
2. Uniform Wear Theory: It is assumed that wear is uniformly distributed over the entire the
surface area of the friction disk. The basic principle in designing machine parts that are
subjected to wear due to sliding friction is that the axial wear is proportional to the friction work.
The work done by the friction force is proportional to the product of frictional force (p) and the
sliding (rubbing) velocity (2
) where N is speed in rev/min. Therefore,
Wear
(p).(2
Assuming wear, speed N and the coefficient of friction is constant for a given configuration
then,
Wear
It may be noted that when the friction surface is new, there is a uniform pressure distribution
over the entire contact surface. This pressure will wear most rapidly where the sliding (rubbing)
velocity is maximum and this will reduce the pressure between the friction surfaces.
Let p be the normal intensity of pressure at a distance r from the axis of the clutch. Since the
intensity of pressure varies inversely with the distance r, therefore
The wear at the outer radius will be more, which will release the pressure at the outer edge
due to the rigid pressure plate. This will change the pressure distribution.
Where pa is the intensity of pressure at the inner edge, which is also the maximum intensity of
pressure. From eq. (1);
.. (4)

Machine Design - 1
. (5)
Divide eq. (5) by eq. (4) we get;
... (6)
The above equation gives the torque transmitting capacity for a single pair of contacting surface.
The uniform pressure theory is applicable only when the frication lining (A protective covering that
protects an inside surface) is new. When lining is put into service, wear occurs. Therefore, the
major portion of the life of frication lining comes under the uniform wear criterion. In the design of
clutches the uniform wear theory if justified. TTC can be increased by three methods:
1. Increases the coefficient of friction (

2. Increases the plate pressure (p)
3. Increases the mean radius of the friction disk
Single Disc or Plate Clutch
A single disc or plate clutch, as shown in Fig d, consists of a clutch plate whose both sides are
faced with a frictional material. It is mounted on the hub which is free to move axially along the
splines of the driven shaft.
fig: d
The pressure plate is mounted inside the clutch body which is bolted to the flywheel. Both the
pressure plate and the flywheel rotate with the engine crankshaft or the driving shaft. The
pressure plate pushes the clutch plate towards the flywheel by a set of strong springs which
are arranged radially inside the body.
Machine Design - 1
When the clutch pedal is pressed down, its linkage forces the thrust release bearing to move in
towards the flywheel and pressing the longer ends of the levers inward. The levers are forced
to turn on their suspended pivot and the pressure plate moves away from the flywheel by the
knife edges, thereby compressing the clutch springs. This action removes the pressure from
the clutch plate and thus moves back from the flywheel and the driven shaft becomes
stationary.
On the other hand, when the foot is taken off from the clutch pedal, the thrust bearing moves
back by the levers. This allows the springs to extend and thus the pressure plate pushes the
clutch plate back towards the flywheel.
If the torque due to this frictional force exceeds the torque to be transmitted, then no slipping
takes place and the power is transmitted from the driving shaft to the driven shaft.
Multi-disk Clutch
A multiple disc clutch, as shown in Fig. e, may be used when a large torque is to be
transmitted. The inside discs are fastened to the driven shaft to permit axial motion. The
outside discs are held by bolts and are fastened to the housing which is keyed to the driving
shaft. The multiple disc clutches are extensively used in motor cars, machine tools etc.
Fig: e
Cone Clutch
A cone clutch, as shown in Fig. f, was extensively used in automobiles, but now-a-days it has
been replaced completely by the disc clutch. It consists of one pair of friction surface only. In a
cone clutch, the driver is keyed to the driving shaft and has an inside conical surface or face which
exactly fits into the outside conical surface of the driven.
The driven member resting on the feather key in the driven shaft, may be shifted along the shaft
by a forked lever provided at B, in order to engage the clutch by bringing the two conical surfaces
in contact.
Machine Design - 1
Due to the frictional resistance set up at this contact surface, the torque is transmitted from one
shaft to another. In some cases, a spring is placed around the driven shaft in contact with the hub
of the driven. This spring holds the clutch faces in contact and maintains the pressure between
them, and the forked lever is used only for disengagement of the clutch.
Fig: f
The semi-cone angle is always
kept greater than the angle of static
friction to avoid self engagement.
The recommended semi-cone angle
is 12.5. The cone are easy to
disengage
and
simple
in
construction. Their main drawback is
the strict requirement for the
coaxiality of two shafts. The
equations for the torque transmitting,
capacity of the cone clutch are
derived in a manner similar to that of
a single-plate clutch. The dimensions
of the friction cone are shown in Fig.
g. An elementry ring of the cone
bounded by circles of radii rand (r +
dr) is considered. For thll elementry
ring:
Fig: g
Design of a Cone Clutch:

From fig. (A)
Area,

Normal Force =
Friction Fore =
xp=2
Machine Design - 1
xp
px
Friction Tourqe =
p x r
(1)
From fig. (B)

Axial Force
=p
sin = =
p (sin )
Intregrating equation (1) and (2) with boundry conditions
(2)
, we get
T=
(3)
F=2
(4)
There are two criteria to obtain torque capacity as follows:

1. When there is a uniform pressure (Uniform Pressure Theory).
2. When there is a uniform wear (Uniform Wear Theory).
1. Uniform pressure theory

From this criterion p is constant, equations (3) and (4) intregrating separately with there
limits/boundry conditions, and then results manipulates, we get
T=

Machine Design - 1
2. Uniform wear theory

From this criterion pr is constant, put pr = p a (d/2) in equations (3) and (4), and then
intregrating separately with there limits/boundry conditions, and then results manipulates, we
get
T=
Centrifugal Clutch
The centrifugal clutches are usually integrated into the motor pulleys. It consists of a number of
shoes on the inside of a rim of the pulley, as shown in Fig. (h). The outer surfaces of the shoes
are covered with a friction material. These shoes, which can move radially in guides, are held
against the boss (or spider) on the driving shaft by means of springs. The springs exert a
radially inward force which is assumed constant.
The weight of the shoe, when revolving causes it to exert a radially outward force (i.e.
centrifugal force). The magnitude of this centrifugal force depends upon the speed at which the
shoe is revolving. A little consideration will show that when the centrifugal force is less than the
spring force, the shoe remains in the same position as when the driving shaft was stationary,
but when the centrifugal force is equal to the spring force, the shoe is just floating.
When the centrifugal force exceeds the spring force, the shoe moves outward and comes into
contact with the driven member and presses against it. The force with which the shoe presses
against the driven member is the difference of the centrifugal force and the spring force.
The increase of speed causes the shoe to press harder and enables more torque to be
transmitted.
Fig: (h)
10
Machine Design - 1
Design of a Centrifugal Clutch

In designing a centrifugal clutch, it is required to following:
1. To determine the mass of the shoe
2. To determine the size of the shoe
3. To determine the dimensions of the spring.
fig: (i)
1. Mass of the Shoe:
Consider one shoe of a centrifugal clutch as shown in Fig. (i).
Let, m = Mass of each shoe,
n = Number of shoes,
r = Distance of centre of gravity of the shoe from the centre of the spider,
R = Inside radius of the pulley rim,
N = Running speed of the pulley in r.p.m.,
= Angular running speed of the pulley in rad / s
=
1 = Angular speed at which the engagement begins to take place, and
= Coefficient of friction between the shoe and rim.
We know that the centrifugal force acting on each shoe at the running speed,
Pc = m.2.r
Since the speed at which the engagement begins to take place is generally taken as 3/4th of
the running speed, therefore the inward force on each shoe exerted by the spring is given
2
by: Ps = m.(1)2.r = m.( )2.r = m.
.r
Net outward radial force (i.e. centrifugal force) with which the shoe presses against the rim
2
at the running speed = Pc - Ps = (m.2.r) (m.
.r)
Frictional force acting tangentially on each shoe, F = (Pc Ps)
Frictional torque acting on each shoe = F R = (Pc Ps) R
Total frictional torque transmitted, T = (Pc Ps) R n = n.F.R
From this expression, the mass of the shoes (m) may be evaluated.
2. Size of the shoes
Let,
= Contact length of the shoes,

b = Width of the shoes,

11
Machine Design - 1
R = Contact radius of the shoes. It is same as the inside radius of the rim of the pulley,
= Angle subtended by the shoes at the centre of the spider in radians, and
p = Intensity of pressure exerted on the shoe. In order to ensure reasonable life, it may be
taken as 0.1 N/mm2.
We know that =
or = .R =
.... (Assuming = 60 = rad)
Area of contact of the shoe = . b

The force with which the shoe presses against the rim = A p = . b . p
Since the force with which the shoe presses against the rim at the running speed is
(Pc Ps),
Therefore, . b . p = Pc Ps
From this expression, the width of shoe (b) may be obtained.
3. Dimensions of the spring
We have discussed above that the load on the spring is given by
2
Ps = (m.
.r)
The dimensions of the spring may be obtained as usual.

12

Machine Design - Design of Clutches

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Brown Hills College of Engineering & Technology

Brown Hills College of Engineering & Technology

1. Deriving member: it consists of a flywheel mounted on the engine crankshaft.

Chart for the types of clutches:

Disc or Plate Clutch

Fluid Clutch or Fluid Flywheel

Brown Hills College of Engineering & Technology

Sachin Chaturvedi Lecturer in Department of Mechanical Engineering

Brown Hills College of Engineering & Technology

Sachin Chaturvedi Lecturer in Department of Mechanical Engineering

Brown Hills College of Engineering & Technology

Divide eq. (2) by eq. (1) we get;

Sachin Chaturvedi Lecturer in Department of Mechanical Engineering

Brown Hills College of Engineering & Technology

Divide eq. (5) by eq. (4) we get;

1. Increases the coefficient of friction (

Brown Hills College of Engineering & Technology

Brown Hills College of Engineering & Technology

Design of a Cone Clutch:

Brown Hills College of Engineering & Technology

From fig. (B)

Intregrating equation (1) and (2) with boundry conditions

There are two criteria to obtain torque capacity as follows:

1. Uniform pressure theory

Sachin Chaturvedi Lecturer in Department of Mechanical Engineering

Brown Hills College of Engineering & Technology

2. Uniform wear theory

Brown Hills College of Engineering & Technology

Design of a Centrifugal Clutch

= Contact length of the shoes,

Sachin Chaturvedi Lecturer in Department of Mechanical Engineering

Brown Hills College of Engineering & Technology

.... (Assuming = 60 = rad)

Area of contact of the shoe = . b

Sachin Chaturvedi Lecturer in Department of Mechanical Engineering

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