Machine

Design II

MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Brakes and Clutches
Parameters

Frictional
Work and
Power MEng154.002
Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Week 4
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II

MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and DISCLAIMER
Power
This presentation may contain errors that will be corrected in class. It is your
Energy to be
absorbed responsibility to take note of the corrections. This may be considered as a
Design of supplementary material only and should not be used as a substitute to the class
Brakes
Block Brakes, Band discussions and reading materials. Not everything you need to know is included in
Brakes, Disk Brakes

Design of
these notes. All the images used here are for educational purposes only and are not
Clutches intended for any commercial use.
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Table of Contents
MEng154.002

1 Clutches
Clutches

Actuation of 2 Actuation of Brakes or Clutches

Brakes or
Clutches
3 Performance Parameters
Performance
Parameters 4 Frictional Work and Power
Frictional
Work and 5 Energy to be absorbed
Power

Energy to be 6 Design of Brakes

absorbed
Block Brakes, Band Brakes, Disk Brakes
Design of
Brakes
Block Brakes, Band
7 Design of Clutches
Brakes, Disk Brakes
Positive Contact Clutches
Design of
Clutches Friction Clutch
Positive Contact
Clutches Cone Clutch
Friction Clutch
Cone Clutch Centrifugal Clutch
Centrifugal Clutch

Friction
8 Friction Materials
Materials
 Machine
Design II Table of Contents
MEng154.002

1 Clutches
Clutches

Actuation of 2 Actuation of Brakes or Clutches

Brakes or
Clutches
3 Performance Parameters
Performance
Parameters 4 Frictional Work and Power
Frictional
Work and 5 Energy to be absorbed
Power

Energy to be 6 Design of Brakes

absorbed
Block Brakes, Band Brakes, Disk Brakes
Design of
Brakes
Block Brakes, Band
7 Design of Clutches
Brakes, Disk Brakes
Positive Contact Clutches
Design of
Clutches Friction Clutch
Positive Contact
Clutches Cone Clutch
Friction Clutch
Cone Clutch Centrifugal Clutch
Centrifugal Clutch

Friction
8 Friction Materials
Materials
 Machine
Design II What are clutches?
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II What are clutches?
MEng154.002

Clutches • required when shafts must be frequently connected and disconnected.

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II What are clutches?
MEng154.002

Clutches • required when shafts must be frequently connected and disconnected.

Actuation of
Brakes or
• a machine member used to connect a driving shaft to a driven shaft so that
Clutches
the driven shaft may be started or stopped at will, without stopping the
Performance
Parameters driving shaft.
Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II What are clutches?
MEng154.002

Clutches • required when shafts must be frequently connected and disconnected.

Actuation of
Brakes or
• a machine member used to connect a driving shaft to a driven shaft so that
Clutches
the driven shaft may be started or stopped at will, without stopping the
Performance
Parameters driving shaft.
Frictional • a mechanism for transmitting rotation, which can be engaged and disengaged.
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Clutches
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Figure 1.0. Simple clutch assembly.
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Brakes
MEng154.002

Clutches • a device used to bring a moving system to rest, to slow its speed down, or to
Actuation of control its speed to a certain value.
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Brakes
MEng154.002

Clutches • a device used to bring a moving system to rest, to slow its speed down, or to
Actuation of control its speed to a certain value.
Brakes or
Clutches • the function of the brake is to turn mechanical energy into heat.
Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Brakes
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch
Figure 1.1. Disk brake assembly.
Friction
Materials
 Machine
Design II Types of Brakes and Clutches
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed (a) Internal, expanding rim type
Design of
Brakes
(b) External, contracting rim type
Block Brakes, Band
Brakes, Disk Brakes
(c) Band brake
Design of (d) Thrust disk
Clutches
Positive Contact
(e) Cone disk
Clutches
Friction Clutch (f) Block brake
Cone Clutch
Centrifugal Clutch
(g) Differential brake
Friction
Materials
 Machine
Design II Types of Brakes and Clutches
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes
(h) Caliper disc brake
Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Types of Brakes and Clutches
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches (i) Short shoe brake
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Types of Brakes and Clutches
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches (j) Long shoe brake
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Types of Brakes and Clutches
MEng154.002

Clutches
1. Thrust pad (disk)
Actuation of • Extremely common and versatile arrangement; can be wet or dry.
Brakes or
Clutches • Wide variety of materials including carbon-carbon composites for aircraft
Performance
Parameters brakes.
Frictional • Preferred for front axles of vehicles because of superior convective cooling;
Work and
Power cannot self-lock.
Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Types of Brakes and Clutches
MEng154.002

Clutches
1. Thrust pad (disk)
Actuation of • Extremely common and versatile arrangement; can be wet or dry.
Brakes or
Clutches • Wide variety of materials including carbon-carbon composites for aircraft
Performance
Parameters brakes.
Frictional • Preferred for front axles of vehicles because of superior convective cooling;
Work and
Power cannot self-lock.
Energy to be
absorbed 2. Cone
Design of • Higher pressure and torque for same size compared to thrust pad due to
Brakes
Block Brakes, Band
Brakes, Disk Brakes
wedging action of cone.
Design of • Common for lower speed applications with little sliding such as washing
Clutches
Positive Contact machines or extractors.
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Types of Brakes and Clutches
MEng154.002

Clutches
3. Block or short-shoe
Actuation of • Available in a wide variety of configurations.
Brakes or
Clutches • Commonly applied to roller coasters, industrial equipment.
Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Types of Brakes and Clutches
MEng154.002

Clutches
3. Block or short-shoe
Actuation of • Available in a wide variety of configurations.
Brakes or
Clutches • Commonly applied to roller coasters, industrial equipment.
Performance
Parameters 4. Long-shoe (drum)
Frictional
Work and
• Widely applied in vehicles on rear axles.
Power
• Self-locking promotes ”parking brake” function.
Energy to be
absorbed • Economical and reliable; Limited heat dissipation capability.
Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Types of Brakes and Clutches
MEng154.002

Clutches
5. Pivot-shoe
Actuation of • Used for low-torque applications in architecture, fishing equipment.
Brakes or
Clutches • Higher torque applications include hoists and cranes.
Performance
Parameters • Difficult to properly locate pivot.
Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Types of Brakes and Clutches
MEng154.002

Clutches
5. Pivot-shoe
Actuation of • Used for low-torque applications in architecture, fishing equipment.
Brakes or
Clutches • Higher torque applications include hoists and cranes.
Performance
Parameters • Difficult to properly locate pivot.
Frictional
Work and 6. Band brakes
Power
• Simple, compact, and rugged.
Energy to be
absorbed • Widely applied to chain saws, go-karts, motorcycles, and some bicycles.
Design of
Brakes • Susceptible to chatter or grabbing.
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Brakes and Clutches Assembly
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Brakes and Clutches Assembly
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Brakes and Clutches Assembly
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Brakes and Clutches Assembly
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Brakes and Clutches Assembly
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Table of Contents
MEng154.002

1 Clutches
Clutches

Actuation of 2 Actuation of Brakes or Clutches

Brakes or
Clutches
3 Performance Parameters
Performance
Parameters 4 Frictional Work and Power
Frictional
Work and 5 Energy to be absorbed
Power

Energy to be 6 Design of Brakes

absorbed
Block Brakes, Band Brakes, Disk Brakes
Design of
Brakes
Block Brakes, Band
7 Design of Clutches
Brakes, Disk Brakes
Positive Contact Clutches
Design of
Clutches Friction Clutch
Positive Contact
Clutches Cone Clutch
Friction Clutch
Cone Clutch Centrifugal Clutch
Centrifugal Clutch

Friction
8 Friction Materials
Materials
 Machine
Design II Actuation of Brakes or Clutches
MEng154.002

Clutches
1. Manual
Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Actuation of Brakes or Clutches
MEng154.002

Clutches
2. Spring-applied
Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Actuation of Brakes or Clutches
MEng154.002

Clutches
3. Centrifugal
Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch Chainsaw clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Actuation of Brakes or Clutches
MEng154.002

Clutches
4. Pneumatic
Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Actuation of Brakes or Clutches
MEng154.002

Clutches
5. Hydraulic
Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Actuation of Brakes or Clutches
MEng154.002

Clutches
6. Electromagnetic
Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Table of Contents
MEng154.002

1 Clutches
Clutches

Actuation of 2 Actuation of Brakes or Clutches

Brakes or
Clutches
3 Performance Parameters
Performance
Parameters 4 Frictional Work and Power
Frictional
Work and 5 Energy to be absorbed
Power

Energy to be 6 Design of Brakes

absorbed
Block Brakes, Band Brakes, Disk Brakes
Design of
Brakes
Block Brakes, Band
7 Design of Clutches
Brakes, Disk Brakes
Positive Contact Clutches
Design of
Clutches Friction Clutch
Positive Contact
Clutches Cone Clutch
Friction Clutch
Cone Clutch Centrifugal Clutch
Centrifugal Clutch

Friction
8 Friction Materials
Materials
 Machine
Design II Performance of Brakes and Clutches
MEng154.002

Clutches
The parameters involved in the rating of brakes and clutches are:
Actuation of 1. Torque to accelerate or decelerate the system
Brakes or
Clutches 2. Time required to accomplish the speed change
Performance 3. The cycling rate: number of on/off cycles per unit time
Parameters
4. The inertia of the rotating or translating parts
Frictional
Work and 5. The environment of the system: temperature, cooling effects, etc.
Power
6. Energy dissipation capability of the clutch
Energy to be
absorbed 7. Physical size and configuration
Design of 8. Means of actuation
Brakes
Block Brakes, Band 9. Life and reliability of the system
Brakes, Disk Brakes

Design of
10. Cost and availability
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Table of Contents
MEng154.002

1 Clutches
Clutches

Actuation of 2 Actuation of Brakes or Clutches

Brakes or
Clutches
3 Performance Parameters
Performance
Parameters 4 Frictional Work and Power
Frictional
Work and 5 Energy to be absorbed
Power

Energy to be 6 Design of Brakes

absorbed
Block Brakes, Band Brakes, Disk Brakes
Design of
Brakes
Block Brakes, Band
7 Design of Clutches
Brakes, Disk Brakes
Positive Contact Clutches
Design of
Clutches Friction Clutch
Positive Contact
Clutches Cone Clutch
Friction Clutch
Cone Clutch Centrifugal Clutch
Centrifugal Clutch

Friction
8 Friction Materials
Materials
 Machine
Design II Frictional Work and Power
MEng154.002

Clutches
Frictional Torque
Actuation of • An important parameter for brakes and clutches.
Brakes or
Clutches • Brake capacity is often expressed in terms of frictional torque.
Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Frictional Work and Power
MEng154.002

Clutches
Frictional Torque
Actuation of • An important parameter for brakes and clutches.
Brakes or
Clutches • Brake capacity is often expressed in terms of frictional torque.
Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch
Figure 1.2. Block brake.
Friction
Materials
 Machine
Design II Frictional Work and Power
MEng154.002

Clutches
Frictional Work
Actuation of
Brakes or
Clutches
W = Force × distance = F × d
Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Frictional Work and Power
MEng154.002

Clutches
Frictional Work
Actuation of
Brakes or
Clutches
W = Force × distance = F × d
Performance
Parameters For a rotating body
Frictional Uf = T dψ (1)
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Frictional Work and Power
MEng154.002

Clutches
Frictional Work
Actuation of
Brakes or
Clutches
W = Force × distance = F × d
Performance
Parameters For a rotating body
Frictional Uf = T dψ (1)
Work and
Power
where dψ radians is the angle the body turns while subjected to any torque T.
Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Frictional Work and Power
MEng154.002

Clutches
Frictional Work
Actuation of
Brakes or
Clutches
W = Force × distance = F × d
Performance
Parameters For a rotating body
Frictional Uf = T dψ (1)
Work and
Power
where dψ radians is the angle the body turns while subjected to any torque T. If Tf is
Energy to be
absorbed constant or assumed to be some average value, frictional work on the surface of
Design of
Brakes
rotating drum of diameter D is then
Block Brakes, Band
Brakes, Disk Brakes
Uf = F (πDNt ) (2)
Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Frictional Work and Power
MEng154.002

Clutches
Combining with Torque formula,
Actuation of
Brakes or
Clutches
Uf = Tf (2πNt ) (3)
Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Frictional Work and Power
MEng154.002

Clutches
Combining with Torque formula,
Actuation of
Brakes or
Clutches
Uf = Tf (2πNt ) (3)
Performance
Parameters

Frictional
Work and
Power
⇓
Energy to be Uf
absorbed
Tf = (4)
Design of 2πNt
Brakes
Block Brakes, Band where:
Brakes, Disk Brakes
Nt - number of turns of the drum
Design of
Clutches Tf - frictional torque
Positive Contact
Clutches Uf - frictional work
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Frictional Work and Power
MEng154.002

Clutches
For constant angular acceleration α
Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Frictional Work and Power
MEng154.002

Clutches
For constant angular acceleration α
Actuation of
Brakes or
Clutches
Tf = Iα (5)
Performance
Parameters where I is the mass moment of inertia of rotating members about the axis of rotation.
Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Frictional Power
MEng154.002

Clutches
Frictional power
Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Frictional Power
MEng154.002

Clutches
Frictional power
Actuation of
Brakes or
Clutches Pf = Tf ω (6)
Performance
Parameters where ω is the angular velocity of the drum ω = 2πn; n is in rps or rpm
Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Frictional Power
MEng154.002

Clutches
Frictional power
Actuation of
Brakes or
Clutches Pf = Tf ω (6)
Performance
Parameters where ω is the angular velocity of the drum ω = 2πn; n is in rps or rpm
Frictional
Work and (Tf ft-lb.) ωm
Power fhp = (7)
Energy to be
33, 000
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Frictional Power
MEng154.002

Clutches
Frictional power
Actuation of
Brakes or
Clutches Pf = Tf ω (6)
Performance
Parameters where ω is the angular velocity of the drum ω = 2πn; n is in rps or rpm
Frictional
Work and (Tf ft-lb.) ωm
Power fhp = (7)
Energy to be
33, 000
absorbed

Design of (Tf in-lb.) n

Brakes
fhp = (8)
Block Brakes, Band
Brakes, Disk Brakes
63, 000
Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Table of Contents
MEng154.002

1 Clutches
Clutches

Actuation of 2 Actuation of Brakes or Clutches

Brakes or
Clutches
3 Performance Parameters
Performance
Parameters 4 Frictional Work and Power
Frictional
Work and 5 Energy to be absorbed
Power

Energy to be 6 Design of Brakes

absorbed
Block Brakes, Band Brakes, Disk Brakes
Design of
Brakes
Block Brakes, Band
7 Design of Clutches
Brakes, Disk Brakes
Positive Contact Clutches
Design of
Clutches Friction Clutch
Positive Contact
Clutches Cone Clutch
Friction Clutch
Cone Clutch Centrifugal Clutch
Centrifugal Clutch

Friction
8 Friction Materials
Materials
 Machine
Design II Energy absorbed
MEng154.002

Clutches
The body being braked may undergo a change in potential energy -∆P E
Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Energy absorbed
MEng154.002

Clutches
The body being braked may undergo a change in potential energy -∆P E
Actuation of
Brakes or
Clutches
−∆P E = W (h1 − h2 ) (9)
Performance
Parameters where W is the weight of the body moved from an elevation h1 to h2 .
Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Energy absorbed
MEng154.002

Clutches
The body being braked may undergo a change in potential energy -∆P E
Actuation of
Brakes or
Clutches
−∆P E = W (h1 − h2 ) (9)
Performance
Parameters where W is the weight of the body moved from an elevation h1 to h2 .
Frictional The change in kinetic energy of a translating body of weight W in lb is
Work and
Power
W 2 2


Energy to be
absorbed
−∆KE = vs1 − vs2 ft-lb (10)
2g
Design of
Brakes
Block Brakes, Band
where:
Brakes, Disk Brakes
vs1 - initial speed
Design of
Clutches
vs2 - final speed
Positive Contact
Clutches
g - local acceleration
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Energy absorbed
MEng154.002

Clutches
For a rotating body, the change in kinetic energy is
Actuation of
Brakes or I 2
ω1 − ω22 ft-lb


Clutches −∆KE = (11)
2
Performance
Parameters
where:
Frictional
Work and I is the moment of inertia of the body about its axis of rotation;
Power
ω1 and ω2 are the initial and final angular velocities.
Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Energy absorbed
MEng154.002

Clutches
For a rotating body, the change in kinetic energy is
Actuation of
Brakes or I 2
ω1 − ω22 ft-lb


Clutches −∆KE = (11)
2
Performance
Parameters
where:
Frictional
Work and I is the moment of inertia of the body about its axis of rotation;
Power
ω1 and ω2 are the initial and final angular velocities.
Energy to be
absorbed For a rolling body,
Design of
Brakes W 2
I 2
v s1 − v 2s2 + ω1 − ω22 ft-lb


Block Brakes, Band −∆KE = (12)
Brakes, Disk Brakes
2g 2
Design of
Clutches
Positive Contact
where the bar over v means that the velocities are for the center of gravity.
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Brake shoe
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Figure 1.3. Brake shoe
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Brake shoe
MEng154.002

Clutches • The permissible normal pressures between the surfaces depend on the
Actuation of brake-lining material, the coefficient of friction, and on the maximum
Brakes or
Clutches rate at which energy is to be absorbed.
Performance
Parameters
• the higher the pressure, the greater is the rate of wear and the energy
Frictional absorbed.
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Brake shoe
MEng154.002

Clutches • The permissible normal pressures between the surfaces depend on the
Actuation of brake-lining material, the coefficient of friction, and on the maximum
Brakes or
Clutches rate at which energy is to be absorbed.
Performance
Parameters
• the higher the pressure, the greater is the rate of wear and the energy
Frictional absorbed.
Work and
Power The pressure on a projected of a shoe is
Energy to be
absorbed N
Design of p= (13)
Brakes A
Block Brakes, Band
Brakes, Disk Brakes
where N is the total normal force.
Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Brake shoe
MEng154.002

Clutches
Actual rate of energy dissipated H
Actuation of
Brakes or
Clutches
H = f N vm = F vm = f pAvm (14)
Performance
Parameters where:
Frictional f - coefficient of friction
Work and
Power
N - normal force
p - pressure on the projected area
Energy to be
absorbed vm - surface velocity
Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Design data
MEng154.002

Clutches
Typical values of pvm for industrial brake shoes:
Actuation of
Brakes or
Clutches pvm = 5500 frequent application
Performance pvm = 16,500 average use
Parameters
pvm = 49,500 infrequent short-time
Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Design data
MEng154.002

Clutches
Typical values of pvm for industrial brake shoes:
Actuation of
Brakes or
Clutches pvm = 5500 frequent application
Performance pvm = 16,500 average use
Parameters
pvm = 49,500 infrequent short-time
Frictional
Work and
Power
According to Raybestor-Manhattan, manufacturer’s design values for pvm
Energy to be
absorbed pvm = 1500 to 10,000
Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Design data
MEng154.002

Clutches
Some pvm values according to Hutte:
Actuation of
Brakes or
Clutches pvm ≦ 55,000
Performance for intermittent load application, comparatively long periods of rest, poor
Parameters
dissipation of heat. for f = 0.25, this is equivalent to 0.42 fhp/sq.in absorbed.
Frictional
Work and pvm ≦ 28,000
Power
for continuous application of the load as in lowering applications, poor dissipation
Energy to be
absorbed of heat. for f = 0.25, this is equivalent to 0.21 fhp/sq.in absorbed.
Design of pvm ≦ 83,000
Brakes
Block Brakes, Band
Brakes, Disk Brakes
for continuous application of the load, good heat dissipation. for f = 0.25, this is
Design of
equivalent to 0.63 fhp/sq.in absorbed.
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Temperature Increase
MEng154.002

Clutches
The temperature increase ∆t of the adjacent metal in the drum wheel
Actuation of
Brakes or Uf ft-lb
Clutches ∆t◦ F = (15)
wm c
Performance
Parameters

Frictional
where:
Work and wm lb is the mass of the metal absorbing the energy Uf
Power
c is the average specific heat of the metal for the temperature range.
Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Brake loading
MEng154.002

Clutches
In automobile brakes, a desirable maximum instantaneous loading is about 2.2
Actuation of fhp/sq.in of brake rubbing surface on the drum.
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Brake loading
MEng154.002

Clutches
In automobile brakes, a desirable maximum instantaneous loading is about 2.2
Actuation of fhp/sq.in of brake rubbing surface on the drum.
Brakes or
Clutches

Performance fade
Parameters

Frictional
• a phenomenon where the effectiveness of the brake greatly decreases short
Work and
Power
after it begins to act continuously.
Energy to be • due to a significant decrease in the coefficient of friction at the high surface
absorbed
temperatures induced.
Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Design References
MEng154.002

Clutches Table AT29. Design Data for Brakes and Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Design References
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Example
MEng154.002

Clutches
A 3000 lb automobile, moving on a level road at 60 mph, is braked so that the
Actuation of deceleration is constant at 20 f ps2 (close to normal maximum) until it stops. (If it
Brakes or
Clutches were going downhill, the loss of PE would be added to the loss of KE; if uphill,
Performance gravity would help slow down the car.) Each cast-iron brake drum is D = 9 in.
Parameters
diameter, b = 2 1/4 in. face width, and t = 3/16 in. thick.
Frictional
Work and (a) Assuming that the radiated and convected heat is negligible, compute the
Power
temperature rise of the drum.
Energy to be
absorbed (b) What is the average rate of power absorption (fhp) during the first second?
Design of During the last second?
Brakes
Block Brakes, Band (c) What is the overall fhp?
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Example
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches Figure 1.4. Brake drum
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Shoe brake design
MEng154.002

Clutches
If the pressure distribution on the internal shoe is
Actuation of
Brakes or
Clutches
p = P sin ϕ (16)
Performance
Parameters Derive the equations for the moments of N with respect to B, moments of F with
Frictional respect to B, and the torque with respect to O.
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Shoe brake design
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Table of Contents
MEng154.002

1 Clutches
Clutches

Actuation of 2 Actuation of Brakes or Clutches

Brakes or
Clutches
3 Performance Parameters
Performance
Parameters 4 Frictional Work and Power
Frictional
Work and 5 Energy to be absorbed
Power

Energy to be 6 Design of Brakes

absorbed
Block Brakes, Band Brakes, Disk Brakes
Design of
Brakes
Block Brakes, Band
7 Design of Clutches
Brakes, Disk Brakes
Positive Contact Clutches
Design of
Clutches Friction Clutch
Positive Contact
Clutches Cone Clutch
Friction Clutch
Cone Clutch Centrifugal Clutch
Centrifugal Clutch

Friction
8 Friction Materials
Materials
 Machine
Design II Short Block Brakes
MEng154.002

Clutches
Consider a short block brake with small θ
Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch Figure 1.5. Short Block Brake.
Centrifugal Clutch

Friction
Materials
 Machine
Design II Short Block Brakes
MEng154.002

Clutches
The summation of moments about A
Actuation of
Brakes or
X F
Clutches MA = W a − N b + F e = W a − b + Fe = 0 (17)
f
Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Short Block Brakes
MEng154.002

Clutches
The summation of moments about A
Actuation of
Brakes or
X F
Clutches MA = W a − N b + F e = W a − b + Fe = 0 (17)
f
Performance
Parameters
If the sense of the moment of F is the same as that for W, the brake is said to be
Frictional
Work and self-energizing or self-actuating.
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Short Block Brakes
MEng154.002

Clutches
In Equation(17), if b/f = e,
Actuation of
Brakes or
Clutches
W =0
Performance
Parameters means that no force is necessary to apply the brake.
Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Short Block Brakes
MEng154.002

Clutches
In Equation(17), if b/f = e,
Actuation of
Brakes or
Clutches
W =0
Performance
Parameters means that no force is necessary to apply the brake.
Frictional If e > b/f ,
Work and
Power
b
Energy to be
absorbed
Wa = F − F e (W is negative)
f
Design of
Brakes
Block Brakes, Band means that a force is necessary to disengage the brake.
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Short Block Brakes
MEng154.002

Clutches
In Equation(17), if b/f = e,
Actuation of
Brakes or
Clutches
W =0
Performance
Parameters means that no force is necessary to apply the brake.
Frictional If e > b/f ,
Work and
Power
b
Energy to be
absorbed
Wa = F − F e (W is negative)
f
Design of
Brakes
Block Brakes, Band means that a force is necessary to disengage the brake.
Brakes, Disk Brakes

Design of
The brake is said to be self-locking.
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Short Block Brakes
MEng154.002

Clutches
Braking or Frictional Torque
Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Short Block Brakes
MEng154.002

Clutches
Braking or Frictional Torque
Actuation of From Equation(17),
Brakes or Wfa
Clutches F = (18)
Performance b − fe
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Short Block Brakes
MEng154.002

Clutches
Braking or Frictional Torque
Actuation of From Equation(17),
Brakes or Wfa
Clutches F = (18)
Performance b − fe
Parameters

Frictional
Multiplying both sides by drum radius D/2,
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Short Block Brakes
MEng154.002

Clutches
Braking or Frictional Torque
Actuation of From Equation(17),
Brakes or Wfa
Clutches F = (18)
Performance b − fe
Parameters

Frictional
Multiplying both sides by drum radius D/2,
Work and
Power
FD W Df a
Energy to be Tf = = (19)
absorbed 2 2 (b − f e)
Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Short Block Brakes
MEng154.002

Clutches
Braking or Frictional Torque
Actuation of From Equation(17),
Brakes or Wfa
Clutches F = (18)
Performance b − fe
Parameters

Frictional
Multiplying both sides by drum radius D/2,
Work and
Power
FD W Df a
Energy to be Tf = = (19)
absorbed 2 2 (b − f e)
Design of
Brakes Mechanical advantage MA
Block Brakes, Band
Brakes, Disk Brakes Tf
MA = (20)
Design of
Clutches
Wa
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Long Block Brakes
MEng154.002

Clutches
Consider a block brake with significantly large θ
Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch Figure 1.6. Long Block (Shoe) Brake.
Centrifugal Clutch

Friction
Materials
 Machine
Design II Long Block Brakes
MEng154.002

Clutches
Assuming:
Actuation of 1. There is a uniform pressure distribution on the drum and shoe.
Brakes or
Clutches 2. Wear is proportional to the pressure.
Performance 3. The pressure distribution is
Parameters

Frictional
Work and
p = P cos α
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Long Block Brakes
MEng154.002

Clutches
Assuming:
Actuation of 1. There is a uniform pressure distribution on the drum and shoe.
Brakes or
Clutches 2. Wear is proportional to the pressure.
Performance 3. The pressure distribution is
Parameters

Frictional
Work and
p = P cos α
Power

Energy to be Consider an element area dA

absorbed

Design of
Brakes dA = b (rdα)
Block Brakes, Band
Brakes, Disk Brakes

Design of where b is the face width and

Clutches
Positive Contact
Clutches
Friction Clutch
rdα = ds
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Long Block Brakes
MEng154.002

Clutches
The normal and frictional forces are
Actuation of
Brakes or
Clutches
dN = pbrdα = P br cos αdα (21)
Performance
Parameters dF = f pbrdα = f P br cos αdα (22)
Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Long Block Brakes
MEng154.002

Clutches
The normal and frictional forces are
Actuation of
Brakes or
Clutches
dN = pbrdα = P br cos αdα (21)
Performance
Parameters dF = f pbrdα = f P br cos αdα (22)
Frictional
Work and The moment of dF about point B is
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Long Block Brakes
MEng154.002

Clutches
The normal and frictional forces are
Actuation of
Brakes or
Clutches
dN = pbrdα = P br cos αdα (21)
Performance
Parameters dF = f pbrdα = f P br cos αdα (22)
Frictional
Work and The moment of dF about point B is
Power

dMF/B = f P br C cos2 α − r cos α dα

Energy to be


absorbed (23)
Design of
Brakes
Block Brakes, Band
⇓
Brakes, Disk Brakes
   θ
Design of α sin 2α 2
Clutches
MF/B = f P br C + − r sin α (24)
Positive Contact
Clutches
2 4 −θ
Friction Clutch
2
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Long Block Brakes
MEng154.002

Clutches
If MF/B = 0,
Actuation of 4r sin θ/2 2D sin θ/2
Brakes or C= = (25)
Clutches θ + sin θ θ + sin θ
Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Long Block Brakes
MEng154.002

Clutches
If MF/B = 0,
Actuation of 4r sin θ/2 2D sin θ/2
Brakes or C= = (25)
Clutches θ + sin θ θ + sin θ
Performance
Parameters
The normal force N
Z  
Frictional θ + sin θ
Work and
Power
N= dN cos α = P br (26)
2
Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Long Block Brakes
MEng154.002

Clutches
If MF/B = 0,
Actuation of 4r sin θ/2 2D sin θ/2
Brakes or C= = (25)
Clutches θ + sin θ θ + sin θ
Performance
Parameters
The normal force N
Z  
Frictional θ + sin θ
Work and
Power
N= dN cos α = P br (26)
2
Energy to be
absorbed
The frictional torque
Design of
Z
Brakes
Block Brakes, Band
Tf = rdF (27)
Brakes, Disk Brakes

Design of
Clutches ⇓
Positive Contact
Clutches
θ
Tf = 2f P br2 sin
Friction Clutch
Cone Clutch (28)
Centrifugal Clutch 2
Friction
Materials
 Machine
Design II Band Brakes
MEng154.002

Clutches
In a band brake, the band wraps partly around the brake wheel or drum, and
Actuation of braking action is done by pulling the band tight onto the wheel.
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch
Figure 1.7. Band Brake.
Friction
Materials
 Machine
Design II Band Brakes
MEng154.002

Clutches
The braking force is
F1
Actuation of = ef θ (29)
Brakes or
Clutches
F2
Performance where F1 is the tenson of the tight side of the band and F2 is the smaller tension.
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Band Brakes
MEng154.002

Clutches
The braking force is
F1
Actuation of = ef θ (29)
Brakes or
Clutches
F2
Performance where F1 is the tenson of the tight side of the band and F2 is the smaller tension.
Parameters
The total frictional force F
Frictional
Work and F = F1 − F2 (30)
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Band Brakes
MEng154.002

Clutches
Consider another band brake as below
Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch Figure 1.8. Differential Band Brake.
Centrifugal Clutch

Friction
Materials
 Machine
Design II Band Brakes
MEng154.002

Clutches
Moment at B X
Actuation of MB = W a + F1 b − F2 c = 0 (31)
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Band Brakes
MEng154.002

Clutches
Moment at B X
Actuation of MB = W a + F1 b − F2 c = 0 (31)
Brakes or
Clutches
The forces are then
Performance
Parameters
F
Frictional F2 =
Work and ef θ−1
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
F ef θ
Brakes, Disk Brakes F1 =
Design of
ef θ − 1
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Band Brakes
MEng154.002

Clutches
Using the values of F1 and F2 , we get the value of W as
Actuation of
F c − bef θ


Brakes or
Clutches W = (32)
Performance
a (ef θ − 1)
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Band Brakes
MEng154.002

Clutches
Using the values of F1 and F2 , we get the value of W as
Actuation of
F c − bef θ


Brakes or
Clutches W = (32)
Performance
a (ef θ − 1)
Parameters

Frictional Multiplying both sides by D/2, then the frictional torque is

Work and
Power
W Da ef θ − 1


Energy to be
absorbed Tf = (33)
2 (c − bef θ )
Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Band Brakes
MEng154.002

Clutches
The pressure p on a band brake
F
Actuation of p= (34)
Brakes or
Clutches
fA
Performance where A is the contact area between the band and the drum.
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Band Brakes
MEng154.002

Clutches
The pressure p on a band brake
F
Actuation of p= (34)
Brakes or
Clutches
fA
Performance where A is the contact area between the band and the drum.
Parameters
Suitable drum diameters (Hagenbook):
Frictional
Work and
Power  1/3  1/3
Tf Tf
Energy to be <D< Tf in-lb
absorbed 5 4
Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Band Brakes
MEng154.002

Clutches
The pressure p on a band brake
F
Actuation of p= (34)
Brakes or
Clutches
fA
Performance where A is the contact area between the band and the drum.
Parameters
Suitable drum diameters (Hagenbook):
Frictional
Work and
Power  1/3  1/3
Tf Tf
Energy to be <D< Tf in-lb
absorbed 5 4
Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of (60 fhp)1/3 < D < (80 fhp)1/3

Clutches
Positive Contact
Clutches
Friction Clutch
where fhp is the max horsepower to be dissipated in any 15-minute period.
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Disk Brakes
MEng154.002

Clutches
Friction surfaces for disk brakes generally have an annular shape
Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction Figure 1.9. Disk Friction.

Materials
 Machine
Design II Disk Brakes
MEng154.002

Clutches
For
Actuation of (1) Uniformly distributed pressure; and
Brakes or
Clutches (b) Uniform wear
Performance The normal force N is Z ro Z
Parameters 2π
Frictional
N= C dθ dρ (35)
Work and ri 0
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Disk Brakes
MEng154.002

Clutches
For
Actuation of (1) Uniformly distributed pressure; and
Brakes or
Clutches (b) Uniform wear
Performance The normal force N is Z ro Z
Parameters 2π
Frictional
N= C dθ dρ (35)
Work and ri 0
Power

Energy to be
absorbed
N = 2πC (ro − ri ) (36)
Design of
Brakes ⇓
Block Brakes, Band
Brakes, Disk Brakes
N
Design of C= (37)
Clutches 2π (ro − ri )
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Disk Brakes
MEng154.002

Clutches
The frictional torque
Tf = πCf ro2 − ri2


Actuation of (38)
Brakes or
Clutches
or
Performance
Parameters
f N (r0 + ri )
Frictional Tf = = f N rm (39)
Work and 2
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Disk Brakes
MEng154.002

Clutches
The frictional torque
Tf = πCf ro2 − ri2


Actuation of (38)
Brakes or
Clutches
or
Performance
Parameters
f N (r0 + ri )
Frictional Tf = = f N rm (39)
Work and 2
Power
where rm is the mean radius of the annular surface
Energy to be
absorbed
ro + ri
Design of rm =
Brakes 2
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Example
MEng154.002

Clutches
A single-block brake has the dimensions: cast-iron wheel of D = 15 in., a = 32 1/2
Actuation of in., c = 9 3/8 in., e = 4 11/16 in., width of contact surface = 2 in. The brake
Brakes or
Clutches block lines with molded asbestos, subtends 80◦ , symmetrical about the center line;
Performance it is permitted to absorb energy at the rate of 0.4 hp/sq.in, n = 200 rpm. Assume
Parameters
that p is constant, that F and N act at K, and compute
Frictional
Work and (a)pvm and the approximate braking torque,
Power
(b) the force W to produced this torque,
Energy to be
absorbed (c) the mechanical advantage,
Design of (d) the temperature rise of the 3/8-in. thick rim, if it absorbs all the energy with
Brakes
Block Brakes, Band operation as specified, in 1 min.
Brakes, Disk Brakes

Design of
(e) How long could this brake be so applied for ∆t = 400◦ F?
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Example - Answers
MEng154.002
f t−lb
Clutches
a. pvm = 37,719 min−in 2 ; Tf = 2640 in − lb

Actuation of b. W = 239.34 lb
Brakes or
Clutches c. M A = 0.339
Performance d. ∆t = 306.08◦ F
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Table of Contents
MEng154.002

1 Clutches
Clutches

Actuation of 2 Actuation of Brakes or Clutches

Brakes or
Clutches
3 Performance Parameters
Performance
Parameters 4 Frictional Work and Power
Frictional
Work and 5 Energy to be absorbed
Power

Energy to be 6 Design of Brakes

absorbed
Block Brakes, Band Brakes, Disk Brakes
Design of
Brakes
Block Brakes, Band
7 Design of Clutches
Brakes, Disk Brakes
Positive Contact Clutches
Design of
Clutches Friction Clutch
Positive Contact
Clutches Cone Clutch
Friction Clutch
Cone Clutch Centrifugal Clutch
Centrifugal Clutch

Friction
8 Friction Materials
Materials
 Machine
Design II Types of Clutches
MEng154.002

Clutches

Actuation of
Brakes or
Clutches 1 Positive Contact
Performance
Parameters
1 Square Jaw
Frictional
2 Spiral Jaw
Work and
Power 2 Friction
Energy to be 1 Single/Multi-plate
absorbed
2 Cone
Design of 3 Centrifugal
Brakes
Block Brakes, Band
Brakes, Disk Brakes 3 Electromagnetic
Design of
Clutches 4 Fluid clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Positive Contact Clutches
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes
• Two halves carrying projections or halves
Design of • One half is fixed and the other can move along the axis
Clutches
Positive Contact
Clutches • Jaws of moving half enter into socket of mating half
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Positive Contact Clutches
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Advantages
Brakes
Block Brakes, Band
• No slip and positive engagement
Brakes, Disk Brakes

Design of
• No heat during engagement/disengagement
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Positive Contact Clutches
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Advantages
Brakes
Block Brakes, Band
• No slip and positive engagement
Brakes, Disk Brakes

Design of
• No heat during engagement/disengagement
Clutches
Positive Contact Drawbacks
Clutches
Friction Clutch
Cone Clutch
• Engages only when stationary or rotate at very low speed
Centrifugal Clutch
• High speed engagement results in shocks
Friction
Materials
 Machine
Design II Friction Clutch - Single Plate
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
• Consists of two flanges, one rigidly keyed to the driving shaft and one
Brakes, Disk Brakes
connected to driven shaft with splines.
Design of
Clutches
Positive Contact
• Actuating force is provided by the spring.
Clutches
Friction Clutch • Power transmission between driving and driven flange is done through friction.
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Friction Clutch - Single Plate
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Advantages
Brakes, Disk Brakes
• Smooth engagement
Design of
Clutches
Positive Contact
• Slips only during engagement
Clutches
Friction Clutch • Acts as safety device
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Friction Clutch - Single Plate
MEng154.002

Clutches
Design Considerations
Actuation of • Selection of friction of material of contact surfaces
Brakes or
Clutches • Designing for sufficient torque capacity
Performance
Parameters • Smooth engagement/disengagement
Frictional
Work and
• Provision for holding contact surface without any external assistance
Power
• Low weight of rotating parts to reduce inertia
Energy to be
absorbed • Provision for taking or compensating for wear
Design of
Brakes • Provision for dissipating heat
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Friction Clutch - Single Plate
MEng154.002

Clutches
Torque Transmitting Capacity
Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of Nomenclature
Brakes
Block Brakes, Band
D, Do - Outer diameter of friction disc
Brakes, Disk Brakes
d, Di - Inner diameter of friction disc
Design of
Clutches p - Intensity of pressure at radius r
Positive Contact
Clutches
P, Fap - Operating axial force
Friction Clutch T - Torque transmitted
Cone Clutch
Centrifugal Clutch f - Coefficient of friction
Friction r - radius of the element dr from the center of the disc
Materials
 Machine
Design II Friction Clutch - Single Plate
MEng154.002

Clutches
Total Axial Load Z Do /2
Actuation of
Brakes or
Fa = 2π prdr (40)
Clutches Di /2
Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Friction Clutch - Single Plate
MEng154.002

Clutches
Total Axial Load Z Do /2
Actuation of
Brakes or
Fa = 2π prdr (40)
Clutches Di /2
Performance
Parameters
Total torque
Z Do /2
Frictional
Work and T = 2πf pr2 dr (41)
Power Di /2
Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Friction Clutch - Single Plate
MEng154.002

Clutches
Uniform Pressure Theory(New clutch)
Actuation of
D2 − Di2


Brakes or
Clutches Total axial load Fap = πp o (42)
Performance 4
Parameters

Frictional
1
Work and
Total torque T = f Fap Dmp (43)
Power 2
Energy to be 2(Do3 −Di3 )
absorbed where Dmp = 3(Do2 −Di2 )
Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Friction Clutch - Single Plate
MEng154.002

Clutches

Actuation of
Brakes or
Clutches
Uniform Wear Theory(Worn out clutch)
Performance
Parameters

Frictional
(Do − Di )
Work and Total axial load Faw = πpmax Di (44)
Power 2
Energy to be
absorbed 1
Total torque T = f Faw Dmw (45)
Design of 2
Brakes
1
Block Brakes, Band
Brakes, Disk Brakes where Dmw = 2 (Do + Di )
Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Comparing Uniform Pressure & Wear Theories
MEng154.002

Clutches
Total torque, T = 12 f Fa Dm
Actuation of
2(D3 −D3 )
Brakes or
Dmp = 3 Do2 −Di2 [Uniform pressure theory]
Clutches ( o i)
Performance 1
Parameters
Dmw = 2 (Do + Di ) [Uniform wear theory]
Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Friction Clutch - Single Plate
MEng154.002

Clutches
Conclusions
Actuation of • Uniform pressure theory is applicable for new friction lining.
Brakes or
Clutches • Uniform wear theory is applicable for worn-out friction lining.
Performance
Parameters • Friction radius for new clutch is slightly greater than worn-out clutches.
Frictional
Work and
• Torque transmission capacity of new clutch is slightly higher.
Power
• Major life of friction lining comes under uniform wear criterion.
Energy to be
absorbed • Logical and safer to use uniform wear theory in the design of clutches.
Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Friction Clutch - Single Plate
MEng154.002

Clutches
Conclusions
Actuation of • Uniform pressure theory is applicable for new friction lining.
Brakes or
Clutches • Uniform wear theory is applicable for worn-out friction lining.
Performance
Parameters • Friction radius for new clutch is slightly greater than worn-out clutches.
Frictional
Work and
• Torque transmission capacity of new clutch is slightly higher.
Power
• Major life of friction lining comes under uniform wear criterion.
Energy to be
absorbed • Logical and safer to use uniform wear theory in the design of clutches.
Design of
Brakes Factors to be considered in the design
Block Brakes, Band
Brakes, Disk Brakes
• Service factor: To compensate for the starting torque
Design of
Clutches • Location of clutch: Low torque capacity requirement
Positive Contact
Clutches
Friction Clutch
• Coefficient of friction
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Friction Clutch - Multi-disk
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed
Disk A Disk B
Design of
Brakes Made of hardened steel Made of bronze
Block Brakes, Band
Brakes, Disk Brakes Connected to driven shaft using Connected by four bolts through
Design of
Clutches
splines holes; Bolts are rigidly fixed to
Positive Contact
Clutches
a rotating drum keyed to driving
Friction Clutch
Cone Clutch
shaft
Centrifugal Clutch Free to move in axial direction Axial forces are provided by means
Friction
Materials
of springs
 Machine
Design II Friction Clutch - Multi-disk
MEng154.002

Clutches
Total torque
1
Actuation of T = if Fa Dm (46)
Brakes or
Clutches
2
Performance where:
Parameters 2(D3 −D3 )
Dm = 3 D22 −D12 [New clutch]
Frictional ( 2 1)
Work and 1
Power Dm = 2 (D1 + D2 ) [Worn-out clutch]
Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Friction Clutch - Multi-disk
MEng154.002

Clutches
Total torque
1
Actuation of T = if Fa Dm (46)
Brakes or
Clutches
2
Performance where:
Parameters 2(D3 −D3 )
Dm = 3 D22 −D12 [New clutch]
Frictional ( 2 1)
Work and 1
Power Dm = 2 (D1 + D2 ) [Worn-out clutch]
Energy to be
absorbed Number of friction surfaces i = i1 + i2 − 1
Design of Number of driving disks, i1 = 2i
Brakes
Block Brakes, Band
Number of driven disks, i2 = 2i + 1
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Friction Clutch - Single disk vs Multi-disk
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Friction Clutch - Wet vs Dry
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Cone Clutch
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes • Consists of inner and outer conical surfaces
Design of
Clutches • Outer cone keyed to driving shaft and inner cone connected to driven shaft
Positive Contact
Clutches
Friction Clutch
• Wedge action causes considerable friction force with a small engaging force
Cone Clutch
Centrifugal Clutch
• Recommended semi-cone angle - 12.5◦
Friction • Strict co-axiality required
Materials
 Machine
Design II Cone Clutch
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power Total axial load
D2 − D12


Energy to be
absorbed Fa = πp 2 (47)
Design of
4
Brakes
Block Brakes, Band
Total torque
Brakes, Disk Brakes f Fa Dm
Design of T = (48)
Clutches 2 sin α
Positive Contact
Clutches 2(D23 −D13 )
Friction Clutch Dm = 3(D22 −D12 )
[New clutch]
Cone Clutch
1
Centrifugal Clutch
Dm = 2 (D1 + D2 ) [Worn-out clutch]
Friction
Materials
 Machine
Design II Cone Clutch
MEng154.002

Clutches • Torque capacity is inversely proportional to sin α

Actuation of
Brakes or
• α < ϕ (angle of static friction) can cause self-engagement
Clutches
• For T = constant, Fa ∞ sin α, small axial force for decrease in semi-cone angle.
Performance
Parameters • TTcone = sin1 α = sin 112.5 = 4.62
plate
Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Centrifugal Clutch
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
• Engages the load after a particular speed
Positive Contact
Clutches • Helps in warm-up and acceleration without load
Friction Clutch
Cone Clutch • Centrifugal force increases with speed which causes engagement of clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Centrifugal Clutch
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of r′ - Drum inner radius

Brakes
Block Brakes, Band
r - Radius of the center of gravity of shoe in engaged position
Brakes, Disk Brakes
w - Weight of each shoe
Design of
Clutches Fc - Centrifugal force
Positive Contact
Clutches
i - Number of shoes
Friction Clutch ω2 - running speed
Cone Clutch
Centrifugal Clutch ω1 - speed at which engagement starts
Friction
Materials
 Machine
Design II Centrifugal Clutch
MEng154.002

Clutches
w
Actuation of
Force during engagement Fc1 = ω2r (49)
Brakes or
Clutches 1000g 1
Performance w
Parameters Outside radial force Fc2 = ω2r (50)
Frictional
1000g 2
Work and w
Power
Spring force Fs = ω2r (51)
Energy to be 1000g 1
absorbed
w
ω22 − ω12 r


Design of Net force on drum Fc = (52)
Brakes 1000g
Block Brakes, Band
Brakes, Disk Brakes w
ω22 − ω12 r


Design of Frictional force Ff = f (53)
Clutches 1000g
Positive Contact
w
ω22 − ω12 rr′
Clutches


Friction Clutch Frictional torque T = f (54)
Cone Clutch 1000g
Centrifugal Clutch

Friction
Materials
 Machine
Design II Table of Contents
MEng154.002

1 Clutches
Clutches

Actuation of 2 Actuation of Brakes or Clutches

Brakes or
Clutches
3 Performance Parameters
Performance
Parameters 4 Frictional Work and Power
Frictional
Work and 5 Energy to be absorbed
Power

Energy to be 6 Design of Brakes

absorbed
Block Brakes, Band Brakes, Disk Brakes
Design of
Brakes
Block Brakes, Band
7 Design of Clutches
Brakes, Disk Brakes
Positive Contact Clutches
Design of
Clutches Friction Clutch
Positive Contact
Clutches Cone Clutch
Friction Clutch
Cone Clutch Centrifugal Clutch
Centrifugal Clutch

Friction
8 Friction Materials
Materials
 Machine
Design II Friction Materials - Desirable Properties
MEng154.002

Clutches • High coefficient of friction

Actuation of
Brakes or
• Constant coefficient of friction for a wide range of temperature
Clutches
• Good thermal conductivity
Performance
Parameters • Unaffected by environmental conditions
Frictional
Work and • Resistance to abrasive and adhesive wear
Power

Energy to be
• Good resilience to provide good distribution of pressure at contacting surface
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Friction Materials - Types
MEng154.002

Clutches

Actuation of
Brakes or
Clutches

Performance
Parameters

Frictional
Work and
Power

Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Friction Materials - Basic Ingredients
MEng154.002

Clutches • Fibers: Rigidity and strength (Steel wool or aramid replacing asbestos)
Actuation of
Brakes or
• Filler: Fills space between fibers and extend lining life (barytes, clay, and
Clutches
calcium carbonate).
Performance
Parameters For metallic lining: fine powder is used as filler.
Frictional • Binder: Glue that holds lining ingredients together (phenylformaldehyde)
Work and
Power • Friction modifiers: Control abrasive properties of lining (Brass and Zinc)
Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Example
MEng154.002

Clutches
1. A plate consists of one pair of contacting surfaces. The inner and outer
Actuation of diameters of the friction disk are 100 and 200 mm, respectively. The coefficient of
Brakes or
Clutches friction is 0.1 and the permissible intensity of pressure is 1 N/mm2 .
Performance (a) Assuming uniform wear theory, calculate the power transmitting capacity of the
Parameters
clutch at 750 rpm.
Frictional
Work and (b) Calculate the power transmitting capacity of the clutch using uniform pressure
Power
theory.
Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials
 Machine
Design II Example
MEng154.002

Clutches
2. A multiple-disk clutch for a machine tool operation has 4 phosphor-bronze
Actuation of driving disks and 5 hardened-steel driven disks. This clutch is rated at 5.8 hp at
Brakes or
Clutches 100 rpm when operated dry. The outside and inside diameters of the disks are
Performance 5-1/2 and 4-3/16 in., respectively.
Parameters
(a) If the pressure between the disks is that recommended for mental on metal in
Frictional
Work and Table AT 29, what coefficient of friction is required to transmit the rated power?
Power
(b) What power may be transmitted for f and p as recommended in Table At 29?
Energy to be
absorbed

Design of
Brakes
Block Brakes, Band
Brakes, Disk Brakes

Design of
Clutches
Positive Contact
Clutches
Friction Clutch
Cone Clutch
Centrifugal Clutch

Friction
Materials