METU ME 308 Machine Elements II Spring 2012

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Prepared by: Orkun zahin
Room: D-03 Phone: 7237
E-mail: ozsahin@metu.edu.tr Date: 16/05/2012

ME 308 MACHINE ELEMENTS II
TUTORIAL 7
COUPLINGS, BRAKES & CLUTCHES

NOTE: Equations are taken from Shigleys Mechanical Engineering Design, 8th
edition, Richard G. Budynas, J. Keith Nisbett.

1) Analyze the rigid sleeve coupling that transmits 40 kW at a speed of 350 rpm. The
coupling is shown in the sketch below.

The rigid sleeve coupling is made of cast iron. It is used for
joining two shafts. The allowable shear stress for the shaft
material is 50 MPa. The material of the key and the shaft is
the same and the coupling is required to transmit 25%
overload. Allowable shear stress for the cast iron is 40
MPa. The width of the key is 16 mm and the thickness is
10 mm and the diameter of the shaft is 52 mm. The bearing
strength of the shaft material is 130 MPa and the cast iron
is 140 MPa.
Cross section of the key is as:

t=10 mm

w=16 mm
The proportions of the rigid sleeve made of cast iron are given as:
1
d 2d 12.5 mm, L 3.5d = + = , D = 80 mm, take the length of each key as 5L/11.
2) The band brake shown below uses woven lining with frictional coefficient of 0.24.
Note that the band can withstand maximum 1MPa of pressure.

Given parameters:
Width of the band, b = 30 mm
Radius of the drum, r = 100 mm
Determine:
a) The brake torque
b) The maximum actuating force that can be applied
c) Self-locking characteristics of the brake

METU ME 308 Machine Elements II Spring 2012
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3) For the double long shoe external drum brake shown in the figure, determine the
maximum force that can be applied on the lever. The maximum permissible pressure
on the brake lining is 1.8 MPa. Also, determine the torque capacity of the brake.
Design parameters of the brake mechanism are:
Face width of the shoes, b = 40 mm
Coefficient of friction between the drum and the shoes, f = 0.3

4) A multiple disc clutch has an outside diameter of 152 mm and inside diameter of
76 mm. The clutch material permits a maximum pressure of 276 kPa and has a
coefficient of friction of 0.2. Uniform wear may be assumed and a brake torque of
320 Nm is to be applied. Determine
a) The actuating force
b) The number of discs needed
c) Actual maximum pressure
d) Initially, the speed of driving side is 400 rpm and driven side is stationary. If the
mass moments of inertia for driving side and driven side are I
1
=30 kg.m
2
and
I
2
=21 kg.m
2
, respectively, what is the engagement time? What would be the
speed just after clutching?
e) For the case in (d), determine the total energy absorbed by the clutch assembly
during engagement.

.
PROBLEM 1 SOLUTION

Operating speed of the shaft is,
2
350 36.7
60
rad s
t
e = =
Transmitted torque is found as:
40000
P T T 1090 N.m
36.7
e = = =
Considering the overload factor, the maximum torque on the shaft is
max
T T(1.25) 1360 N.m = =
1
d 2d 12.5 117 mm = + = , note this is only for geometrical design.
L 3.5d 182 mm = =
Now the maximum shear stress on rigid sleeve is checked:
( )
( )
3
max
max
4 4 4 4
4 4
sleeve,max
T
16T 16(1360 10 )(80)
16.5 MPa
d (80 52 )
d
D
D Tr
2
J D
D
32
t
t
t
t

= =

= = =
The allowable stress is 40 MPa, hence the sleeve is safe.
Shear stress induced in the key is calculated as:
max
key
shear
F 1
39.5 MPa 50 MPa (it is safe)
5L
A
w
11
T
d
2
t = = = <
The bearing stress induced in the key:
key, bearing
max
bearing
F 1
126 MPa
5L
A
11
t
2
T
d
2
o = = =
key,b key,b,all
o o < , so the key is safe under bearing stress as well.




METU ME 308 Machine Elements II Spring 2012
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PROBLEM 2 SOLUTION

a)


According to the direction of rotation, larger forces occur at points A and B for upper
and lower bands, respectively. Also the maximum pressure p
a
occurs on BD band
(lower band).

Since member CD is a two force member, from the equilibrium conditions:
*
2 1
P P =

Therefore for the lower band;

Angle of wrap, = 60
From eq. 16-21:
1 a
P p br 1(50)100 5000 N = = = b=30mm

From eq. 16-19:
1
2 f
0.24( )
3
P 5000
P 3889 N
e
e
t o
= = =

For the upper band;

*
1 2
P P 3889 N = =

Angle of wrap,
2
= 140
From eq. 16-19:
2
*
* 1
2 7 f
0.24( )
9
P 3889
P 2163 N
e
e
t o
= = =
Since the brake has upper and lower bands, torque capacity of the brake is the sum of
the brake capacities of the lower and upper bands.

For the upper band:

( ) ( )
* *
1 1 2
T P P r 3889 2163 0.1 172.6 N.m = = =

For the lower band:

( ) ( )
2 1 2
T P P r 5000 3889 0.1 111.1 N.m = = =

Total brake capacity is:

T 283.7 N.m =
b) Free body diagram of the actuating lever is:




O

METU ME 308 Machine Elements II Spring 2012
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Moment equilibrium about pivot point, O, of the lever gives force required:

*
O 2 1
M F 275 P cos(50)75 P cos(50)75 0 = =

( ) ( )
*
2 1
P P cos(50)75 3889 3889 cos(50)75
F 1364 N
275 275
+ +
= = =


c) This band-type brake is self-energizing. The condition of being self-locking is such
that force required to actuate braking is smaller than or equal to zero ( 0 F s ). In that
condition there would be no need for any braking force, thus brake would be self-
locking. But this time there would be requirement for a disengaging force when one
needs to stop braking action. So it is better to set the actuating force greater than zero.
For self-locking condition, 0 F s :


PROBLEM 3 SOLUTION

As a first notice, the left-hand shoe in this brake is self-energizing, while the right-
hand shoe is not self-energizing (for the given rotation direction). Because of its self-
energizing effect, the torque capacity of the left-hand shoe is expected to be higher.
However, here there is a need to investigate the moment arms of both shoes. The
shoes do not have same moment arm, also they do not have same brake force. The
force on the lever arm distributes unevenly between the shoes.
F
Fr1
Fr2
Fl
Fr

Note the l stands for left-hand shoe, and r stands for right-hand shoe. Now, one
needs to find the brake forces on the shoes in terms of lever force, F.
From the moment equilibrium on the pin at the bottom (pin of right-hand shoe):
(150) (50) 0 3
l l
M F F F F = = =

From force equilibriums:
1 1
2 2
0 3
0
x l r r l
y r r
F F F F F F
F F F F F
= = = =
= = =

After finding the forces acting on the shoes, it is now possible to pass to the analysis
of the brake mechanism. To understand the system better, the below figure is used to
represent the shoes separately.





METU ME 308 Machine Elements II Spring 2012
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In the above figure, it can be seen clearly that left-hand shoe is self-energizing, but
right-hand shoe is not. Notice that, the pins where the R forces are applied
correspond to hinged ends of the shoes.
The left-hand shoe is considered firstly, as it has the maximum pressure applied on it.
The explanation of this fact comes from the self-energizing property of the left-hand
shoe. For left-hand shoe, the frictional moment, M
f
, has a decreasing effect on the
moment of normal forces, M
N
. This maximizes the normal force on the shoe, thus
maximizing the pressure. However, if right-hand shoe is considered, the maximum
possible M
N
is limited by M
f
. So, the lever force is considered with respect to the left-
hand shoes torque capacity, and then the torque capacity of the right-hand shoe is
considered.
The shoes in this brake mechanism have same geometrical parameters. The only
difference between them is the direction of M
f
. So, M
f
and M
N
are found for the left-
hand shoe and same values are applied to the right-hand shoe.
For left-hand shoe:
When looked at the detailed figure, it is seen that the left-hand shoe is just a rotated
version of the horizontal one. So, the equations derived in the textbook (eqn.16-2 and
eqn.16-3) can be directly used. The first figure can be checked while finding the
necessary variables of the equations. The variables used in the formula are:
( )
2 2
1
1
2
120 15 121 mm
15
=tan 7.1
120
20 20 7.1 12.9
20 130 137
1.8 MPa
100 mm
o
o
o
a
a
p
r
|
u |
u |

= + =
=
= = =
= + =
=
=

Also, note that since
2
>90, maximum pressure occurs at
a
=90.
From eqn.16-2:
( )
2
1
2
1
137
6
12.9
sin( )( cos( ))
sin( )
1
cos( ) cos(2 )
sin( ) 4
0.3(1.8 10 )0.040(0.100) 1
0.100cos( ) 0.121 cos(2 )
sin(90) 4
314 N.m
a
f
a
a
f
a
f
f
fp br
M r a d
fp br
M r a
M
M
u
u
u u
u u
u
u
u u u
u
u u
u
u u
=
=
=
=
=
( | |
=
| (
\ .
(
= +
(

=
}

From eqn.16-3:
2
1
2
1
2
1
2
137
6
12.9
sin ( )
sin( )
1 cos(2 )
sin( ) 2
1
sin(2 )
sin( ) 2 4
1.8 10 (0.040)0.100(0.121) 1
sin(2 )
sin(90) 2 4
1255 N.m
a
N
a
a
N
a
a
N
a
N
N
p bra
M d
p bra
M d
p bra
M
M
M
u
u
u
u
u u
u u
u
u
u u
u
u
u
u
u
u
u
u
u
=
=
=
=
=
| |
=
|
\ .
(
=
(

(
=
(

=
}
}

Moment equilibrium around the hinge gives the lever force:
(0.120 0.115 0.050) 0
1255 314 3( )0.285 0
1100 N
N f l
M M M F
F
F
= + + =
=
=

Torque capacity of the left-hand shoe from eqn.16-6 is:

METU ME 308 Machine Elements II Spring 2012
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2
1 2
6 2
(cos( ) cos( ))
sin( )
0.3(1.8 10 )0.040(0.100 )(cos(12.9) cos(137))
sin(90)
368.5 N.m
a
L
a
L
L
fp br
T
T
T
u u
u

=

=
=

For right-hand shoe:
Since the lever force is found, the torque capacity of the right-hand shoe can be found.
At first, the maximum pressure on the right-hand shoe should be found. Frictional
moment and moment of normal forces of the right-hand shoe is proportional to the
values of the left-hand shoe (since dimensions are the same).
314 1255
&
1.8 1.8
a a
f N
p p
M M = =
Moment equilibrium around the hinge:
1 2
0.080
(0.115 0.120) ( 0.020) 0
2
1255 314
3( )0.235 (0.015) 0
1.8 1.8
872 0.72
For 1100 N 0.9 MPa
N f r r
a a
a
a
M M M F F
p p
F F
p F
F p
= + + + =
+ + =
=
= =

Torque capacity of the right-hand shoe is:
2
1 2
6 2
(cos( ) cos( ))
sin( )
0.3(0.9 10 )0.040(0.100 )(cos(12.9) cos(1137))
sin(90)
184 N.m
a
R
a
R
R
fp br
T
T
T
u u
u

=

=
=

So, the braking capacity of the mechanism is:
368.5 184 552.5 N.m
L R
T T T = + = + =

PROBLEM 4 SOLUTION

a) Assuming the clutch operates under the maximum permissible pressure of its
material, then the actuating force is (from eqn.16-23):
( )
2
a
p d
F D d
t
=



b) The torque capacity of the clutch (from eqn.16-25):

(2500)0.2
( ) (0.152 0.076) 28.5
4 4
Ff
T D d Nm = + = + =

The total torque is 320 Nm, then the number of friction surfaces n is.

320
11.2
28.5
n = =

Round up and take n as 12

Total number of discs = n+1= 13



c) Then, the torque capacity of one friction surface is

320
26.7 N.m
12
T = =

The necessary actuating force can be found by rearranging eq. 16-28.c as




METU ME 308 Machine Elements II Spring 2012
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Then the actual maximum pressure is




d) It is given in the case that:
1 1 2 2
2
400 rpm 400 =41.9 rad/s & 0
60
t
u e u e = = = = =
Taking linear angular acceleration during the engagement, from eqn.16-51, the
engagement time is:

1 2 1 2
1
1 2
( ) (30)21(41.9 0)
1.62 s.
( ) 320(30 21)
I I
t
T I I
e e
= = =
+ +


Just after engagement, the speeds of both sides are equal,
1 2 f
u u u = = :
1 1 2 1
1 2
OR
24.7 rad/s 236 rpm
f f
f
T T
t t
I I
u e u e
u
= = +
= =


e) From eqn.16-52, energy absorbed is:
2 2
1 2 1 2
1 2
( ) (30)21(41.9 0)
2( ) 2(30 21)
10.8 kJ
I I
E
I I
E
e e
= =
+ +
=