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+ Transmit large torque with no slip + Develop very little heat, because they do not depend upon friction. + Generally lighter. + Less costly than a friction clutches of similar torque capacity. - Can not be engaged at high speeds, max 60 rpm for jaw clutches, and 300 rpm for toothed clutches - Shock accompanies engagement at any speed - Require some relative motion in order to engage when both driving and driven shafts are at rest
Friction clutches
Transmit power from the driving shaft to the driven shaft by means of plates, disks or cones
+ Because they can slip relative to each other, there is very little shock during engagement. + Can be used for high speed engagement applications.
- Do slip - Do wear out (requiring replacement of friction material) - Heat is developed (might require external cooling)
Clutches and brakes are essentially the same device. Each provides a frictional, magnetic, hydraulic or mechanical connection between two elements. Clutches: if both connected elements can rotate; primary function is to transmit power on an intermittent basis. Brakes: if one element rotates and the other is fixed; absorbs the kinetic energy of moving bodies and controls their motions.
Requirements of the clutch : Torque transmission Gradual engagement Heat dissipation Dynamic balancing Vibration damping Inertia
Torque capacity of the clutch depends on : Coefficient of friction The diameter of the driven plate Spring thrust applied by the pressure plate
Limitations of capacity : max available is 0.35 , higher than these clutch becomes unstable increasing dia increases its inertia & it will continue to spin after disengagement there is a limit to clamping pr. To which friction lining material subjected if it is to maintain friction properties over a long period of time.
Torque Transmitted by the clutch : Torque transmitted T = n * F * R F frictional force = * P - coefficient of friction : P Axial load : n number of plates R effective mean radius of frictional surface - Torque transmitted depends on the radius of the friction material. - A limit on the spring force is set by the magnitude of the effort a driver may be expected to exert on a clutch pedal . - is constant for a given material . - n can be increased to transmit more torque.
Clutch
Types of Clutches : Single plate clutch Multiple plate clutch Cone clutch Diaphragm clutch Semi-centrifugal clutch Centrifugal clutch Method of clutch actuation : Mechanical Hydraulic Vacuum Electro magnetic
Materials
Various materials have been used for the disc friction facings, including asbestos in the past. Modern clutches typically use acompound organic resin with copper wire facing or a ceramic material. A typical coefficient of friction used on a friction disc surface is 0.35 for organic and 0.25 for ceramic. Ceramic materials are typically used in heavy applications such as trucks carrying large loads or racing, though the harder ceramic materials increase flywheel and pressure plate wear. Push/Pull Friction disk clutches generally are classified as push type or pull type depending on the location of the pressure plate fulcrum points. In a pull type clutch, the action of pressing the pedal pulls the release bearing, pulling on the diaphragm spring and disengaging the vehicle drive. The opposite is true with a push type, the release bearing is pushed into the clutch disengaging the vehicle drive. In this instance, the release bearing can be known as a thrust bearing (as per the image above). Pads Clutch pads are attached to the frictional pads, part of the clutch. They are most commonly made of rubber but have been known to be made of asbestos. Clutch pads usually last about 100,000 miles (160,000 km) depending on how vigorously the car is driven. Dampers In addition to the damped disc centres which reduce driveline vibration, pre-dampers may be used to reduce gear rattle at idle by changing the natural frequency of the disc. These weaker springs are compressed solely by the radial vibrations from an idling engine. They are fully compressed and no longer in use once drive is taken up by the main damper springs. Load Mercedes truck examples: A clamp load of 33 kN is normal for a single plate 430. The 400 Twin application offers a clamp load of a mere 23 kN. Bursts speeds are typically around 5,000 rpm with the weakest point being the facing rivet. Manufacturing
Wet vs. dry A wet clutch is immersed in a cooling lubricating fluid which also keeps the surfaces clean and gives smoother performance and longer life. Wet clutches, however, tend to lose some energy to the liquid. Since the surfaces of a wet clutch can be slippery (as with a motorcycle clutch bathed in engine oil), stacking multiple clutch discs can compensate for the lower coefficient of friction and so eliminate slippage under power when fully engaged. The Hele-Shaw clutch was a wet clutch that relied entirely on viscous effects, rather than on friction. A dry clutch, as the name implies, is not bathed in fluid and should be, literally, dry.
Clutch housing
Diaphragm spring
Pressure plate
Clutch Disc The clutch disc, also called friction lining, consists of a splined hub and a round metal plate covered with friction material (lining). The splines in the center of the clutch disc mesh with the splines on the input shaft of the manual transmission. This makes the input shaft and disc turn together. However, the disc is free to slide back and forth on the shaft. Clutch disc torsion springs, also termed damping springs, absorb some of the vibration and shock produced by clutch engagement. They are small coil springs located between the clutch disc splined hub and the friction disc assembly. When the clutch is engaged, the pressure plate jams the stationary disc against the spinning flywheel. The torsion springs compress and soften, as the disc first begins to turn with the flywheel. Clutch disc facing springs, also called the cushioning springs, are flat metal springs located under the friction lining of the disc. These springs have a slight wave or curve, allowing the lining to flex inward slightly during initial engagement. This also allows for smooth engagement. The clutch disc friction material, also called disc lining or facing, is made of heatresistant asbestos, cotton fibers, and copper wires woven or molded together. Grooves are cut into the friction material to aid cooling and release of the clutch disc. Rivets are used to bond the friction material to both sides of the metal body of the disc.
Torsional springs
Friction lining
Friction lining Linings are riveted or boned to the clutch plates . Rivet heads seated in counter bores in the friction material , and it is made of copper or aluminium , with this only thickness of the lining down to the rivet heads can be used and remainder has to be scrapped . Bonded lining can utilize large portion of the total volume of the friction material . Friction materials are woven or moulded . - by spinning asbestos or other mineral fibers into a yarn , in some instances on a brass wire core which is woven into a cloth and then impregnated with a bonding agent. It is subdivided into solid woven and laminated. In the former , the cloth is woven to the required thickness of the lining before impregnation ,while in the later several layers of the cloth are placed together and then impregnated . - moulded types made by mixing the fibres and bonding agent into a dough and then moulding it under presure at elevated temp at dies
Release fingers
When the pressure is applied to the foot pedal, the pressure is transmitted through the release finger, fork and release bearing. Then the springs are compressed and its moves back the pressure disc thus releasing the clutch plate. Now the clutch is said to be disengaged. At this stage the pressure plate and flywheel are free to rotate with the clutch plate stationary. Similarly, when the clutch pedal is released, spring pressure is fully applied on the clutch plate. The plate is held between the flywheel and the pressure plate rotates as a single unit. Typical friction disc travels about 0.06 inch(1.5 mm). Sometimes a clutch with greater holding power is needed. When limited space prevents making the clutch larger, the a clutch with two friction disc can be used.