Clutches and Brakes

Clutches and brakes
Mechanical Design
Mechanical Design
PRN Childs, University of Sussex
Aims
A clutch is a device that permits the smooth,
gradual connection of two shafts rotating at
different speeds.
A brake enables the controlled dissipation of
energy to slow down, stop or control the speed
of a system.
This section describes the basic principles of
frictional clutches and brakes and outlines
design and selection procedures for disc
clutches, disc and drum brakes.
Mechanical Design
Learning objectives
At the end of this section you should be able to

determine:
the primary dimensions for a single disc clutch,
the principal dimensions and number of discs for
a multiple disc clutch,
torque capacity for short or long, internal or
external brakes,
the configuration of a brake to be selfenergising.
Mechanical Design
Introduction
When a rotating machine is started it must
be accelerated from rest to the desired
speed.
A clutch is a device used to connect or
disconnect a driven component from a
prime mover such as an engine or motor.
Mechanical Design
Automotive clutches
A familiar application is the use of a clutch between a car
engines crankshaft and the gearbox.
The need for the clutch arises from the relatively high
torque requirement to get a vehicle moving and the low
torque output from an internal combustion engine at low
levels of rotational speed.
The disconnection of the engine from the drive enables
to engine to speed up unloaded to about 1000 rpm
where it is generating sufficient torque to drive the
transmission.
The clutch can then be engaged, allowing power to be
transmitted to the gearbox, transmission shafts and
wheels.
Mechanical Design
Brakes
A brake is a device used to reduce or
control the speed of a system or bring it to
rest.
Mechanical Design
Typical applications for a clutch

and a brake
MOTOR OR
ENGINE
COUPLING
CLUTCH
GEAR BOX
COUPLING
DRIVEN
MACHINE
MOTOR OR
ENGINE
BRAKE
CONNECTION
TO DRIVEN
MACHINE
Mechanical Design
Classification
Clutches and brakes are similar devices
providing frictional, magnetic or
mechanical connection between two
components.
If one component rotates and the other is
fixed to a non-rotating plane of reference
the device will function as a brake and if
both rotate then as a clutch.
Mechanical Design
Force, torque and energy

Whenever the speed or direction of motion
of a body is changed there is force exerted
on the body.
If the body is rotating, a torque must be
applied to the system to speed it up or
slow it down.
If the speed changes, so does the energy,
either by addition or absorption.
Mechanical Design
Acceleration
The acceleration, , of a rotating machine
is given by
T
=
I
where
T is the torque (N m) and
I is the mass moment of inertia (kg m2).
Mechanical Design
Mass moment of inertia

The mass moment of inertia can often be
approximated by considering an assembly
to be made up of a series of cylinders and
discs and summing the individual values
for the disc and cylinder mass moments of
inertia.
Mechanical Design
Mass moments of inertia

The mass moments of inertia for a cylinder
and a disc are given by
1
4
4
Icylinder = L ro ri
2
1
Idisc = Lro4
2
Mechanical Design
Clutch or brake location

Torque is equal to the ratio of power and angular
velocity.
In other words torque is inversely proportional to
angular velocity.
This implies that it is usually advisable to locate
the clutch or brake on the highest speed shaft in
the system so that the required torque is a
minimum.
Size, cost and response time are lower when the
torque is lower.
Mechanical Design
Friction clutches
Friction type clutches and
brakes are the most common.
Two or more surfaces are
pushed together with a normal
force to generate a friction
torque.
Normally, at least one of the
surfaces is metal and the other
a high friction material referred
to as the lining.
The frictional contact can occur
radially, as for a cylindrical
arrangement, or axially as in a
disc arrangement.
FRICTION
MATERIAL
OUTPUT
ACTUATOR
PUSHES DISCS
TOGETHER
DRIVEN
DISC
INPUT
Mechanical Design
DRIVING
DISC
Function
The function of a frictional clutch or brake
surface material is to develop a substantial
friction force when a normal force is applied.
Ideally a material with a high coefficient of
friction, constant properties, good resistance to
wear and chemical compatibility is required.
Clutches and brakes transfer or dissipate
significant quantities of energy and their design
must enable the absorption and transfer of this
heat without damage to the component parts of
the surroundings.
Mechanical Design
Supply
With the exception of high volume automotive
clutches and brakes, engineers rarely need to
design a clutch or a brake from scratch.
Clutch and brake assemblies can be purchased
from specialist suppliers and the engineers task
is to specify the torque and speed requirements,
the loading characteristics and the system
inertias and to select an appropriately sized
clutch or brake and the lining materials.
Mechanical Design
Clutches
The function of a clutch is to permit the
connection and disconnection of two shafts,
either when both are stationary or when there is
a difference in the relative rotational speeds of
the shafts.
Clutch connection can be achieved by a number
of techniques from direct mechanical friction,
electromagnetic coupling, hydraulic or
pneumatic means or by some combination.
Mechanical Design
Types of clutch
SQUARE JAW
POSITIVE
CONTACT
SPIRAL JAW
TOOTHED
METHOD OF
ACTUATION
DISC
FRICTION
MECHANICAL
CONE
PNEUMATIC
AND HYDRAULIC
METHOD OF
ENGAGEMENT
DRUM
ROLLER
OVERRUNNING
SPRAG
ELECTRICAL
SPRING WOUND
MAGNETIC
MAGNETIC PARTICLE
MAGNETIC
HYSTERESIS
EDDY CURRENT
FLUID
COUPLING
Mechanical Design
DRY FLUID
HYDRAULIC
Requirements
Clutches must be designed principally to satisfy

four requirements:
the necessary actuation force should not be
excessive,
the coefficient of friction should be constant,
the energy converted to heat must be dissipated,
wear must be limited to provide reasonable
clutch life.
Mechanical Design
Positive contact clutches

Positive contact
clutches have teeth or
serrations, which
provide mechanical
interference between
mating components.
Mechanical Design
Over-running clutches
Over-running clutches operate automatically based on
the relative velocity of the mating components.
They allow relative motion in one direction only.
If the rotation attempts to reverse the constituent
components of the clutch grab the shaft and lock up.
Applications include backstops, indexing and
freewheeling.
The range of overrunning clutches the simple ratchet
and pawl, roller, sprag and spring wound clutches.
Mechanical Design
Ratchet and pawl clutch
Mechanical Design
Roller clutch
Mechanical Design
Sprag clutch
Mechanical Design
Centrifugal clutches
Centrifugal clutches engage automatically when the shaft speed
exceeds some critical value.
Friction elements are forced radially outwards and engage against
the inner radius of a mating cylindrical drum.
Common applications of centrifugal clutches include chainsaws,
overload-releases and go-karts.
SHOE
RETAINING SPRING
DRIVEN ELEMENT
DRIVING ELEMENT
Mechanical Design
Clutch selection criteria (Neale

(1994))
TYPE OF CLUTCH
CHARACTERISTICS
TYPICAL APPLICATIONS
Sprag
One way clutch. Profiled elements jam against the outer

edge to provide drive. High torque capacity.
One way operation. e.g. backstop

for hoists.
Roller
One way clutch. Rollers ride up ramps and drive by

wedging into place.
One way operation.
Cone clutch
Embodies the mechanical principle of the wedge which

reduces the axial force required to transmit a given
torque.
Contractors plant. Feed drives for

machine tools.
Single disc clutch
Used when diameter

construction
Automobile drives.
Multiple disc clutch
The power transmitted can be increased by using more

plates allowing a reduction in diameter.
Machine
tool
Motorcycles.
head
stocks.
Centrifugal clutch
Automatic engagement at a critical speed.
Electric motor drives.

diesel drives.
Industrial
Magnetic
Compact. Low wear.
Machine tool gearboxes. Numerical

control machine tools.
is
not
restricted.
Simple
Mechanical Design
Clutch design
Clutches are rarely designed from scratch.
Either an existing design is available and is
being modified for a new application or a clutch
can be bought in from a specialist manufacturer.
In the latter case the type, size and the materials
for the clutch lining must be specified.
This requires determination of the system
characteristics such as speed, torque, loading
characteristic and operating temperatures.
Many of these factors have been lumped into a
multiplier called a service factor.
Mechanical Design
Service factor
A lining material is typically tested under
steady conditions using an electric motor
drive.
The torque capacity obtained from this test
is then de-rated by the service factor
according to the particular application to
take account of vibrations and loading
conditions.
Mechanical Design
Disc clutch
PRESSURE
PLATE
COVER
PRESSING
OR CASTING
FLYWHEEL
CASTING
HELICAL
SPRINGS
FRICTION
PLATE
THRUST
BEARING
MOVE AXIALLY
TO DISENGAGE
CRANKSHAFT OR
MOTOR SHAFT
SPLINE OR
KEYED DRIVE
SPIGOT
BEARING
CLUTCH
PLATE DRIVE
Mechanical Design
DRIVEN OR
GEARBOX END
Disc clutch
Engaged
Disengaged
PRESSURE
PLATE
PRESSURE
PLATE
COVER
PRESSING
OR CASTING
FLYWHEEL
CASTING
HELICAL
SPRINGS
FRICTION
PLATE
THRUST
BEARING
MOVE AXIALLY
TO DISENGAGE
CRANKSHAFT OR
MOTOR SHAFT
SPLINE OR
KEYED DRIVE
SPIGOT
BEARING
CLUTCH
PLATE DRIVE
MOVE AXIALLY
TO ENGAGE
CRANKSHAFT OR
MOTOR SHAFT
DRIVEN OR
GEARBOX END
Mechanical Design
SPLINE OR
KEYED DRIVE
CLUTCH
PLATE DRIVE
DRIVEN OR
GEARBOX END
Multiple disc clutch

DRIVEN
DISCS
HYDRAULIC CYLINDER.
PRESSURISE TO
ENGAGE CLUTCH
BUSH
BEARING
DRIVEN
END
OIL SUPPLY FOR

HYDRAULIC CYLINDER
DRIVING
END
SPLINED
SHAFT
SEALS
DRIVING
DISCS
Mechanical Design
Disc clutches
Disc clutches can consist of single or
multiple discs.
Generally multiple disc clutches enable
greater torque capacity but are harder to
cool.
Frictional clutches can be run dry or wet
using oil.
Typical coefficients of friction are 0.07 for
a wet clutch and 0.45 for a dry clutch.
Mechanical Design
Running a clutch wet

While running a clutch wet in oil reduces
the coefficient of friction it enhances heat
transfer and the potential for cooling of the
components.
The expedient solution to the reduction of
the friction coefficient is to use more discs
and hence the use of multiple disc
clutches.
Mechanical Design
Assumptions
Two basic assumptions are used in the
development of procedures for disc clutch
design based upon a uniform rate of wear
at the mating surfaces or a uniform
pressure distribution between the mating
surfaces.
The equations for both of these methods
are outlined in this section.
Mechanical Design
Elemental annular ring

The area of an
elemental annular
ring on a disc clutch is
A=2rr.
Now F=pA, where p is
the assumed uniform
interface pressure, so
F=2rpr.
Mechanical Design
Normal force
For the disc the normal force acting on the
entire face is
ro
2
ro
r
F = 2rpdr = 2p
ri
2 r
F = p r ri
2
o
Note that F is also the necessary force

required to clamp the clutch discs
together.
Mechanical Design
Friction torque
The friction torque T that can be
developed on an elemental ring is the
product of the elemental normal force,
given by F and the radius:
T=rF=2r2pr
where is the coefficient of friction which
models the less than ideal frictional
contact which occurs between two
surfaces.
Mechanical Design
Total torque
The total torque is given by integration
between the limits of the annular ring, ri
and ro:
T=
ro
ri
r
2r pdr = 2p
3
2
ro
ri
2
= p ro3 ri3
3
This equation represents the torque

capacity of a clutch with a single frictional
interface. In practice clutches use an even
number of frictional surfaces.
Mechanical Design
Torque capacity with N faces

For a clutch with N faces the torque
capacity is given by:
2
T = pN ro3 ri3
3
Mechanical Design
Torque capacity
Substituting for the pressure, p, gives an
equation for the torque capacity as a
function of the axial clamping force.
ro3 ri3
2
T = FN 2 2
3
ro ri
Mechanical Design
Uniform wear
The equations assuming uniform wear are
developed below.
The wear rate is assumed to be
proportional to the product of the pressure
and velocity. So
pr = constant
Mechanical Design
Maximum pressure
For a constant angular velocity the
maximum pressure will occur at the
smallest radius.
pmaxri = constant
Eliminating the angular velocity and
constant gives a relationship for the
pressure as a function of the radius:
p = p max
ri
r
Mechanical Design
Dynamic friction coefficients, permissible

contact pressures and temperature limits
MATERIAL
dry
oil
pmax (MN/m)
T (oC)
Moulded compounds
0.25 - 0.45
0.06 - 0.10
1.035 - 2.07
200 - 260
Woven materials
0.25 - 0.45
0.08 - 0.10
0.345 - 0.69
200 - 260
Sintered metal
0.15 - 0.45
0.05 - 0.08
1.035 -2.07
230 - 680
Cork
0.30 - 0.50
0.15 - 0.25
0.055 - 0.1
80
Wood
0.20 - 0.45
0.12 - 0.16
0.345 - 0.62
90
Cast iron
0.15 - 0.25
0.03 - 0.06
0.69- 1.725
260
Paper based
0.10 - 0.17
Graphite/resin
0.10 - 0.14
Mechanical Design
Axial force
The elemental axial force on an elemental
annular ring is given by
F = 2prr
Integrating to give the total axial force:
F=
ro
ri
2prdr =
ro
ri
2p max
ri
rdr = 2p max ri (ro ri )
r
Mechanical Design
Torque
The elemental torque is given by
T = rF
T=
ro
ri
2p max rirdr = p max ri ro2 ri2
Rearranging gives
p max
F
=
2ri (ro ri )
Mechanical Design
Torque
Substituting gives
F
F r ri
(ro + ri )
T=
=
2 ro ri
2
For N frictional surfaces
2
o
T=
ro
ri
2Np max rirdr = p max Nri r ri

NF
(ro + ri )
T=
2
Mechanical Design
2
o
maximum torque for any outer

radius
By differentiating with respect to ri and
equating the result to zero, the maximum
torque for any outer radius ro is found to
occur when
ri = 1/3ro
This useful formula can be used to set the
inner radius if the outer radius is
constrained to a particular value.
Mechanical Design
Design
Clutches are usually designed based on uniform
wear.
The uniform wear assumption gives a lower
torque capacity clutch than the uniform pressure
assumption.
The preliminary design procedure for disc clutch
design requires the determination of the torque
and speed, specification of space limitations,
selection of materials, and the selection of
principal radii, ro and ri.
Common practice is to set the value of ri
between 0.45ro and 0.8ro.
Mechanical Design
Procedure
1)
2)
3)
4)
5)
6)
The procedure for determining the initial

geometry is itemised below.
Determine the service factor.
Determine the required torque capacity,
T=power/.
Determine the coefficient of friction .
Determine the outer radius ro.
Find the inner radius ri.
Find the axial actuation force required.
Mechanical Design
Materials
The material used for clutch plates is
typically grey cast iron or steel.
The friction surface will consist of a lined
material which may be moulded, woven,
sintered or solid.
Moulded linings consist of a polymeric
resin used to bind powdered fibrous
material and brass and zinc chips.
Mechanical Design
Example
A clutch is required for transmission of
power between a four cylinder internal
combustion engine and a small machine.
Determine the radial dimensions for a
single face dry disc clutch with a moulded
lining which should transmit 5 kW at 1800
rpm.
Base the design on the uniform wear
assumption.
Mechanical Design
Example
Mechanical Design
Solution
A service factor of two
should be used.
The design will
therefore be
undertaken using a
power of 25 kW=10
kW.
TYPE OF
DRIVER
DESCRIPTION OF
GENERAL
SYSTEM
TYPICAL
DRIVEN
SYSTEM
SMALL
ELECTRIC
MOTORS,
TURBINE
IC
ENGINES
(4 TO 6
CYLINDER
S).
MEDIUM
TO LARGE
ELECTRIC
MOTORS
IC
ENGINES
(2 OR 3
CYLINDER
S)
SINGLE
CYLINDER
ENGINE
Steady power
source, steady
load, no shock or
overload
Belt drive, small

generators,
centrifugal
pumps, fans,
machine tools
1.5
1.7
1.9
2.2
Steady power
source
Light machinery
for wood, metal
and textiles,
conveyor belts
2.0
2.4
2.7
with some
irregularity of load
up to 1.5 times
nominal power
Larger conveyor
belts, larger
machines,
reciprocating
pumps
2.2
2.4
2.7
Frequent startstops,
Presses,
Punches, piston
pumps, Cranes,
hoists
2.5
2.7
2.9
3.2
overloads, cycling,
high inertia starts,
high power,
pulsating power
source
Stone crushers,
roll mills, heavy
mixers, single
cylinder
compressors
3.0
3.2
3.4
3.7
Mechanical Design
1.8
2.0
Solution cont.
The torque is given by
Power
10000
T=
=
= 53 N m
1800 (2 / 60 )
From Table 10.3 taking mid range values

for the coefficient friction and the
maximum permissible pressure for
moulded linings gives =0.35 and
pmax=1.55 MN/m2.
Mechanical Design
Solution cont.
MATERIAL
dry
oil
pmax (MN/m)
T (oC)
Moulded compounds
0.25 - 0.45
0.06 - 0.10
1.035 - 2.07
200 - 260
Woven materials
0.25 - 0.45
0.08 - 0.10
0.345 - 0.69
200 - 260
Sintered metal
0.15 - 0.45
0.05 - 0.08
1.035 -2.07
230 - 680
Cork
0.30 - 0.50
0.15 - 0.25
0.055 - 0.1
80
Wood
0.20 - 0.45
0.12 - 0.16
0.345 - 0.62
90
Cast iron
0.15 - 0.25
0.03 - 0.06
0.69- 1.725
260
Paper based
0.10 - 0.17
Graphite/resin
0.10 - 0.14
Mechanical Design
Solution cont.
ri = 1/ 3 ro
Taking
T=
1/3ropmax r
2
o
1/3pmax
( 1/3r )
1 3
r ro =
3
3
o
Mechanical Design
4/27pmaxro3
Solution cont.
ro =
1/3
pmax 4/27
53.05
6
0.35 1.55 10 4/27
1/3
= 0.04324 m
ri = 1/ 3 ro = 0.02497 m
Mechanical Design
Solution cont.
F = 2 ri pmax (ro ri ) =
2 0.02497 1.55 106 (0.04324 0.02497) =

4443 N
So the clutch consists of a disc of inner and
outer radius 25 mm and 43 mm respectively,
with a moulded lining having a coefficient of
friction value of 0.35 and a maximum
permissible contact pressure of 1.55 MPa and
an actuating force of 4.4 kN.
Mechanical Design
Example
A disc clutch, running in oil, is required for
a vehicle with a four-cylinder engine. The
design power for initial estimation of the
clutch specification is 90 kW at 4500 rpm.
Determine the radial dimensions and
actuating force required. Base the design
on the uniform wear assumption.
Mechanical Design
Solution
From Table 10.2 a
service factor of 2.7
should be used to
account for starts and
stops and the four
cylinder engine. The
design will therefore
be undertaken using
a power of 2.790 =
243 kW.
TYPE OF
DRIVER
DESCRIPTION OF
GENERAL
SYSTEM
TYPICAL
DRIVEN
SYSTEM
SMALL
ELECTRIC
MOTORS,
TURBINE
IC
ENGINES
(4 TO 6
CYLINDER
S).
MEDIUM
TO LARGE
ELECTRIC
MOTORS
IC
ENGINES
(2 OR 3
CYLINDER
S)
SINGLE
CYLINDER
ENGINE
Steady power
source, steady
load, no shock or
overload
Belt drive, small

generators,
centrifugal
pumps, fans,
machine tools
1.5
1.7
1.9
2.2
Steady power
source
Light machinery
for wood, metal
and textiles,
conveyor belts
2.0
2.4
2.7
with some
irregularity of load
up to 1.5 times
nominal power
Larger conveyor
belts, larger
machines,
reciprocating
pumps
2.2
2.4
2.7
Frequent startstops,
Presses,
Punches, piston
pumps, Cranes,
hoists
2.5
2.7
2.9
3.2
overloads, cycling,
high inertia starts,
high power,
pulsating power
source
Stone crushers,
roll mills, heavy
mixers, single
cylinder
compressors
3.0
3.2
3.4
3.7
Mechanical Design
1.8
2.0
Solution cont.
Power
243000
T=
=
= 515.7 N m
4500 (2 / 60 )
From Table 10.3 taking mid range values

for the coefficient friction and the
maximum permissible pressure for
moulded linings gives =0.35 and
pmax=1.55 MN/m2.
Mechanical Design
Solution cont.
Taking
ri = 1/ 3 ro
ro =
1/3
T
Npmax 4/27
515.7
0.35 2 1.55 106 4/27
1/3
= 0.07325 m
ri = 1/ 3 ro = 0.04229 m
Mechanical Design
Solution cont.
F = 2 Nri pmax (ro ri ) = 2 2 0.04229
1.55 10 (0.07325 0.04229) = 25500 N

6
So the clutch consists of a disc of inner and

outer radius 42.3 mm and 73.3 mm respectively,
with a moulded lining having a coefficient of
friction value of 0.35 and a maximum
permissible contact pressure of 1.55 MPa and
an actuating force of 25.5 kN.
Mechanical Design
Example
A multiple disc clutch, running in oil, is
required for a motorcycle with a threecylinder engine.
The power demand is 75 kW at 8500 rpm.
The preliminary design layout indicates
that the maximum diameter of the clutch
discs should not exceed 100 mm.
Mechanical Design
Example cont.
In addition previous designs have
indicated that a moulded lining with a
coefficient of friction of 0.068 in oil and a
maximum permissible pressure of 1.2 MPa
is reliable.
Within these specifications determine the
radii for the discs, the number of discs
required and the clamping force.
Mechanical Design
Solution
T=
Service factor Power
3.4 75000
= 286.5 N m
8500 (2 /60)
Mechanical Design
Solution cont.
Select the outer radius to be the largest
possible, i.e. ro=50 mm.
Using ri = 1/ 3 ro
ri=28.87 mm.
Mechanical Design
Solution cont.
The number of frictional surfaces, N
N=
pmax ri (r ri
2
o
286.5
= 23.23
6
2
2
1.2 10 0.02887 0.068(0.05 0.02887 )
This must be an even number, so the

number of frictional surfaces is taken as
N=24. This requires thirteen driving discs
and twelve driven discs to implement.
Mechanical Design
Solution cont.
The clamping force can be calculated:
2T
2 286.5
=
= 4452 N
F=
N(ro + ri ) 0.068 24(0.05 + 0.02887 )
Mechanical Design
Brakes
The basic function of a brake is to absorb
kinetic energy and dissipate it in the form
of heat.
Mechanical Design
Example
An idea of the magnitude of energy that
must be dissipated can be obtained from
considering the familiar example of a car
undergoing an emergency stop in seven
seconds from 60 mph (96 km/h).
Mechanical Design
Solution
If the cars mass is 1400 kg and assuming
that 65% of the cars weight is loaded onto
the front axles during rapid braking then
the load on the front axle is
1400 9.81 0.65 = 8927 N
Mechanical Design
Solution cont.
This will be shared between two brakes so
the energy that must be absorbed by one
brake is
1
2
2
E = m Vi Vf
2
1 8927
0.5
E=
2
9.81
96 10
3600
Mechanical Design
= 161.8 kJ
Solution cont.
If the car brakes uniformly in seven
seconds then the heat that must be
dissipated is 161.8103/7=23.1 kW.
From your experience of heat transfer
from say 1 kW domestic heaters you will
recognise that this is a significant quantity
of heat to transfer away from the relatively
compact components that make up brake
assemblies.
Mechanical Design
Heat transfer
Convective heat transfer can be modelled by Fouriers
equation:
Q = hAT = hA (Ts Tf )
This equation indicates that the ability of a brake to
dissipate the heat generated increases as the surface
area increases or as the heat transfer coefficient rises.
For air, the heat transfer coefficient is usually dependent
on the local flow velocity and on the geometry.
A method often used for disc brakes to increase both the
surface area and the local flow is to machine multiple
axial or radials holes in the disc.
Mechanical Design
Types of brake
SHORT SHOE
METHOD OF
ACTUATION
DRUM
MECHANICAL
PNEUMATIC
AND HYDRAULIC
LONG SHOE
BAND
FRICTION
METHOD OF
ENGAGEMENT
DISC
ELECTRICAL
CALIPER DISC
FULL DISC
AUTOMATIC
MAGNETIC
ELECTRICALLY ON
ELECTRICALLY OFF
Mechanical Design
Comparative table of brake

performance
TYPE OF BRAKE
MAXIMUM
OPERAT
ING
TEMPER
ATURE
BRAKE
FACTOR
STABILITY
DRYNESS
DUST
AND
DIRT
TYPICAL
APPLICATIO
NS
Differential band
brake
Low
High
Low
Unstable but
effective
still
Good
Winches,
hoist,
excavators,
tractors
External
drum
brake
(leading
trailing
edge)
Low
Medium
Medium
Unstable if humid,
poor if wet
Good
Mills,
Internal
drum
brake
(leading
trailing
edge)
Higher
than
external
brake
Medium
Medium
Unstable if humid,
ineffective
if
wet
Good if sealed
Vehicles (rear axles

on passenger
cars)
Internal
drum
brake (two
leading
shoes)
Higher
than
external
brake
High
Low
Unstable if humid,
ineffective
if
wet
Good if sealed
Vehicles (rear axles

on passenger
cars)
Mechanical Design
elevators,
winders
Self-energising brakes
Brakes can be designed so that, once
engaged the actuating force applied is
assisted by the braking torque.
This kind of brake is called a selfenergising brake and is useful for braking
large loads.
Mechanical Design
Self-locking
Great care must be exercised in brake
design.
It is possible and sometimes desirable to
design a brake, which once engaged, will
grab and lock up (called self-locking
action).
Mechanical Design
Disc brakes
Disc brakes are familiar
from automotive
applications where they
are used extensively for
vehicle wheels.
These typically consist of
a cast iron disc, bolted to
the wheel hub.
This is sandwiched
between two pads
actuated by pistons
supported in a calliper
mounted on the stub
shaft.
STUB-AXLE
CALIPER
PADS
DISC
Mechanical Design
SEAL
SEAL
WHEEL
HUB
HYDRAULIC
CYLINDER
Torque capacity
With reference to the figure, the torque capacity
per pad is given by
T = Fre
where re is an effective radius.

F
re
ri
ro
ANNULAR PAD
Mechanical Design
CIRCULAR PAD
Actuating force
The actuating force assuming constant
pressure is given by
ro2 ri2
F = p av
2
or assuming uniform wear by
F = p max ri (ro ri )
Mechanical Design
The relationship between the average and

the maximum pressure for the uniform
wear assumption is given by
p av
2ri / ro
=
p max 1 + ri / ro
Mechanical Design
Effective radius
For an annular disc brake the effective
radius is given, assuming constant
pressure, by
(
(
2 ro3 ri3
re =
3 ro2 ri2
)
)
and assuming uniform wear by

ri + ro
re =
2
Mechanical Design
Circular pad disk brake design

values (Fazekas, (1972))
For circular pads the
effective radius is
given by re=r, where
values for are given
in the table as a
function of the ratio of
the pad radius and
the radial location, R/r
R/r
=re/r
pmax/pav
1.000
1.000
0.1
0.983
1.093
0.2
0.969
1.212
0.3
0.957
1.367
0.4
0.947
1.578
0.5
0.938
1.875
Mechanical Design
Actuating force
The actuating force for circular pads can
be calculated using:
F = R p av
2
Mechanical Design
Example
A calliper brake is required for the front wheels
of a sports car with a braking capacity of 820 N
m for each brake.
Preliminary design estimates have set the brake
geometry as ri=100 mm, ro=160 mm and =45o.
A pad with a coefficient of friction of 0.35 has
been selected.
Determine the required actuating force and the
average and maximum contact pressures.
Mechanical Design
Solution
The torque capacity per pad =
820/2 = 410 N m.
The effective radius is
0.1 + 0.16
re =
= 0.13 m
2
Mechanical Design
Solution cont.
The actuating force is given by
T
410
=
= 9.011 kN
F=
re 0.35 0.13
The maximum contact pressure is

pmax
45 (2
F
=
=
ri (ro ri )
9.011 103
= 1.912 MN/m2
/36) 0.1 (0.16 0.1)
Mechanical Design
Solution cont.
The average pressure is given by
p av = p max
2ri / ro
= 1.471 MN / m 2
1 + ri / ro
Mechanical Design
Drum brakes
Drum brakes apply friction to the external or internal
circumference of a cylinder.
A drum brake consists of the brake shoe, which has the
friction material bonded to it, and the brake drum.
For braking, the shoe is forced against the drum
developing the friction torque.
Drum brakes can be divided into two groups depending
on whether the brake shoe is external or internal to the
drum.
A further classification can be made in terms of the
length of the brake shoe: short, long or complete band.
Mechanical Design
Short and long shoe internal drum

brakes
Short shoe internal brakes are used for
centrifugal brakes that engage at a particular
critical speed.
Long shoe internal drum brakes are used
principally in automotive applications.
Drum brakes can be designed to be selfenergising.
Once engaged the friction force increases the
normal force non-linearly, increasing the friction
torque as in a positive feedback loop.
Mechanical Design
Stability
One problem associated some drum brakes is stability.
If the brake has been designed so that the braking
torque is not sensitive to small changes in the coefficient
of friction, which would occur if the brake is worn or wet,
then the brake is said to be stable.
If a small change in the coefficient of friction causes a
significant change to the braking torque the brake is
unstable and will tend to grab if the friction coefficient
rises or the braking torque will drop noticeably if the
friction coefficient reduces.
Mechanical Design
Short shoe external drum brakes

BRAKE
LEVER
y
PIVOT
Ff
SHOE
Fn
DRUM
a
Mechanical Design
Fa

If the included angle of contact between
the brake shoe and the brake drum is less
than 45o, the force between the shoe and
the drum is relatively uniform and can be
modelled by a single concentrated load Fn
at the centre of the contact area.
If the maximum permissible pressure is
pmax the force Fn can be estimated by
Fn = pmaxrw
Mechanical Design

The frictional force, Ff, is given by
Ff = Fn
where is the coefficient of friction.
The torque on the brake drum is
T = Ffr = Fnr
Mechanical Design

Summing moments, for the shoe arm,
about the pivot gives:
Mpivot = aFa bFn + cFf = 0

bFn cFf
b c
= Fn
Fa =
a
a
Mechanical Design

Resolving forces
gives the reactions at
the pivot:
Rx=-Ff
Ry=Fa-Fn
BRAKE
LEVER
y
PIVOT
Ff
SHOE
Fn
DRUM
a
Mechanical Design
Fa

Note that for the configuration and
direction of rotation shown, the friction
moment Fnc adds or combines with the
actuating moment aFa.
Once the actuating force is applied the
friction generated at the shoe acts to
increase the braking torque.
This kind of braking action is called selfenergising.
Mechanical Design

If the brake direction is reversed the
friction moment term Fnc becomes
negative and the applied load Fa must be
maintained to generate braking torque.
This combination is called self deenergising.
Mechanical Design

From
bFn cFf
b c
Fa =
= Fn
a
a
note that if the brake is self-energising and if

c>b then the force required to actuate the
brake is zero or negative and the brake action is
called self-locking.
If the shoe touches the drum it will grab and
lock.
This is usually undesirable with exceptions being
hoist stops or over-running clutch type
applications.
Mechanical Design
Long shoe external drum brakes

If the included angle of contact between
the brake shoe and the drum is greater
than 45o then the pressure between the
shoe and the brake lining cannot be
regarded as uniform and the
approximations made for the short shoe
brake analysis are inadequate.
Most drum brakes use contact angles
greater than 90o.
Mechanical Design

For a single block brake
the force exerted on the
drum by the brake shoe
must be supported by the
bearings.
To balance this load and
provide a compact
braking arrangement two
opposing brake shoes are
usually used in a calliper
arrangement.
LEVER
Ff
Fn
1
PIVOT
Mechanical Design
Fa
SHOE
2
r
DRUM
a
SHOE
Fa
2
r
DRUM
Fa

The braking torque T is given by
p max
(cos 1 cos 2 )
T = wr
(sin )max
2
This is based on the assumption that the

local pressure p at an angular location is
related to the maximum pressure, pmax, by
p max sin
p=
(sin )max
Mechanical Design

With the direction of
rotation shown (i.e.
the brake is selfenergising), the
magnitude of the
actuation force is
given by
LEVER
Ff
Fn
1
PIVOT
Mn Mf
Fa =
a
2
r
DRUM
a
Mechanical Design
SHOE
Fa

The normal and frictional moments can be
determined using
wrbp max 1
1
( 2 1 ) (sin 2 2 sin 21 )
Mn =
(sin )max 2
4
wrp max
b
Mf =
r (cos 1 cos 2 ) + (cos 2 2 cos 21 )
(sin )max
4
Mechanical Design

If the direction of
rotation for the drum
shown is reversed,
the brake becomes
self de-energising and
the actuation force is
given by
LEVER
Ff
Fn
1
PIVOT
Mn + M f
Fa =
a
Mechanical Design
SHOE
2
r
DRUM
a
Fa
Example
Design a long shoe drum brake to produce
a friction torque of 75 N m to stop a drum
rotating at 140 rpm.
Initial design calculations have indicated
that a shoe lining with =0.25 and using a
value of pmax=0.5106 N/m2 in the design
will give suitable life.
Mechanical Design
Solution
First propose trial values for the brake
geometry, say r=0.1 m, b=0.2 m, a=0.3 m,
1=30o, 2=150o.
Mechanical Design
Solution cont.
Solving for the width of the shoe,
T (sin
w= 2
r pmax (cos
)max
cos
75sin90
= 0.0346 m
2
6
0.25 0.1 0.5 10 (cos30 cos150 )
Select the width to be 35 mm as this is a

standard size.
Mechanical Design
Solution cont.
The actual maximum pressure
experienced, will be:
6 0.0346
2
p max = 0.5 10
= 494900 N / m
0.035
Mechanical Design
Solution cont.
The moment of the normal force with
respect to the shoe pivot is:
0.035 0.1 0.2 0.4949 10
Mn =
sin90
1
2
1
120
(sin300 sin60) = 512.8 N m
2
360
4
6
Mechanical Design
Solution cont.
The moment of the frictional forces with
respect to the shoe pivot is:
0.25 0.035 0.1 0.4949 106
Mf =
sin90
0.2
(cos300 cos60)
0.1(cos30 cos150 ) +
4
=75 N m
Mechanical Design
Solution cont.
The actuation force is
Mn M f 512.8 75
Fa =
=
= 1459 N
a
0 .3
Mechanical Design
Double long shoe external drum

brake
For the double long shoe
external drum brake illustrated,
the left hand shoe is selfenergising and the frictional
moment reduces the actuation
load.
The right hand shoe, however,
is self de-energising and its
frictional moment acts to
reduce the maximum pressure
which occurs on the right hand
brake shoe.
Mechanical Design
SHOE
Fa
2
r
DRUM
Fa
Normal and frictional moments

The normal and frictional moments for a
self-energising and self de-energising
brake are related by
'
Mnp max
Mn '=
p max
'
Mf p max
Mf '=
p max
Mechanical Design
Example
79.37
200
115
50
00
R1
130
120
For the double long shoe

external drum brake
illustrated in following
figure determine the
limiting force on the lever
such that the maximum
pressure on the brake
lining does not exceed
1.4 MPa and determine
the torque capacity of the
brake.
Mechanical Design
20
20
Example cont.
The face width of the shoes is 30 mm and
the coefficient of friction between the
shoes and the drum can be taken as 0.28.
Mechanical Design
Solution
First it is necessary to calculate values for
1 and 2 as these are not indicated
directly on the diagram.
1 = 20 tan
o
2 = 20 + 130 tan
o
20
o
= 10.54
120
20
= 140.5 o
120
Mechanical Design
Solution cont.
The maximum value of sin would be
sin90=1.
The distance between the pivot and the
drum centre,
b = 0.02 + 0.12 = 0.1217 m
2
Mechanical Design
Solution cont.
The normal moment is given by
wrbp max 1
1
( 2 1 ) (sin 2 2 sin 21 )
Mn =
(sin )max 2
4
0.03 0.1 0.1217 1.4 106
=
sin90
1
2
1
(140.5 10.54)
(sin281 sin21.08) =
2
360
4
751.1 N m
Mechanical Design
Solution cont.
wrp max
b
Mf =
r (cos 1 cos 2 ) + (cos 2 2 cos 21 )
(sin )max
4
0.28 0.03 0.1 1.4 106
=
sin90
0.1217
(cos281 cos21.08) =
0.1(cos10.54 cos140.5) +
4
179.8 N m
Mechanical Design
Solution cont.
The orthogonal distance between the
actuation force and the pivot,
a=0.12+0.115+0.05=0.285 m.
The actuation load on the left hand shoe is
given by
Fa left shoe
Mn M f 751 .1 179 .8
=
=
= 2004 N
a
0.285
Mechanical Design
Solution cont.
The torque contribution from the left hand
shoe is given by
p max
2
(cos 1 cos 2 )
Tleft shoe = wr
(sin )max
= 0.28 0.03 0.12 1.4 10 6 (cos 10.54 cos 140.5 )
=206.4 N m.
Mechanical Design
Solution cont.
The actuation force
on the right hand
shoe can be
determined by
considering each
member of the lever
mechanism as a free
body.
B
C
79.37
50
A
200
a left shoe
=2004 N
200
50
14.04
a right shoe
Mechanical Design
=2065 N
F=501 N
Solution cont.
F-AV+BV=0.
AH=BH.
BH=CH
AH=CH.
0.2F=0.05BH,
F=BH/4.
BH=2004 N.
F=2004/4=501 N.
B
C
79.37
50
A
200
a left shoe
=2004 N
200
50
14.04
a right shoe
Mechanical Design
=2065 N
F=501 N
Solution cont.
So the limiting lever force is F=501 N.
CV=0, BV=0.
The actuating force for the right hand lever
is the resultant of F and BH.
The resultant angle is given by
tan-1(0.05/0.2)=14.04o.
2004
= 2065 N
Fa right shoe =
cos14.04
Mechanical Design
Solution cont.
14.04
Mechanical Design
235
14.04
223.2
The orthogonal
distance between the
actuation force vector
and the pivot, is given
by
a=(0.2350.01969tan14.04)cos
14.04 = 0.2232 m
19.69
Solution cont.
The normal and frictional moments for the
right hand shoe can be determined using
'
'
Mnp max
751.1p max
Mn '=
=
p max
1.4 10 6
'
'
M f p max
179.8p max
M f '=
=
p max
1.4 10 6
Mechanical Design
Solution cont.
For the right hand shoe the maximum
pressure can be determined from
+Mf '
Mn '
= 2065 =
Farightshoe =
a
'
'
751.1pmax
179.8pmax
6
1.4 10 0.2232
'
p max
= 1.130 10 6 N / m 2
Mechanical Design
Solution cont.
The torque contribution from the right hand
shoe is
Tright shoe
'
p
2
max
(cos 1 cos 2 )
= wr
(sin )max
= 0.28 0.03 01
. 113
. 10 (cos10.54 cos140.5)
=166.6 N m
2
Mechanical Design
Solution cont.
The total torque is given by
Ttotal=Tleft shoe+Tright shoe=
206.4+166.6=373 N m
Mechanical Design
Long Shoe Internal Drum Brakes

Most drum brakes use internal shoes that
expand against the inner radius of the drum.
Long shoe internal drum brakes are principally
used in automotive applications.
An automotive drum brake typically comprises
two brake shoes and linings supported on a
back plate bolted to the axle casing.
The shoes are pivoted at one end on anchor
pins or abutments fixed onto the back plate.
Mechanical Design

SHOE
TOE
HYDRAULIC
CYLINDER
ROTATION
RETRACTION
SPRING
LEADING
SHOE
TRAILING
SHOE
r
DRUM
2
rp
BRAKE
LINING
ANCHOR
PINS OR
ABUTMENTS
SHOE
HEEL
Mechanical Design

The brake can be actuated by a double
hydraulic piston expander, which forces
the free ends of the brake apart so that the
non-rotating shoes come into frictional
contact with the rotating brake drum.
A leading and trailing shoe layout consists
of a pair of shoes pivoted at a common
anchor point.
Mechanical Design
Leading shoe
The leading shoe is
identified as the shoe
whose expander piston
moves in the direction of
rotation of the drum.
The frictional drag
between the shoe and the
drum will tend to assist
the expander piston in
forcing the shoe against
the drum and this action
is referred to as selfenergising or the selfservo action of the shoe.
SHOE
TOE
HYDRAULIC
CYLINDER
ROTATION
RETRACTION
SPRING
LEADING
SHOE
TRAILING
SHOE
r
DRUM
2
rp
BRAKE
LINING
ANCHOR
PINS OR
ABUTMENTS
Mechanical Design
SHOE
HEEL
Trailing shoe
The trailing shoe is the
one whose expander
piston moves in the
direction opposed the
rotation of the drum.
The frictional force
opposes the expander
and hence a trailing brake
shoe provides less
braking torque than an
equivalent leading shoe
actuated by the same
force.
SHOE
TOE
HYDRAULIC
CYLINDER
ROTATION
RETRACTION
SPRING
LEADING
SHOE
TRAILING
SHOE
r
DRUM
2
rp
BRAKE
LINING
ANCHOR
PINS OR
ABUTMENTS
Mechanical Design
SHOE
HEEL

The equations developed for external long
shoe drum brakes are also valid for
internal long shoe drum brakes.
Mechanical Design
Example
Fa
DRUM
R68
Determine the actuating

force and the braking
capacity for the double
internal long shoe brake
illustrated.
The lining is sintered
metal with a coefficient of
friction of 0.32 and the
maximum lining pressure
is 1.2 MPa.
The drum radius is 68
mm and the shoe width is
25 mm.
Fa
16
48
120
LINING
55
SHOE
Mechanical Design
15
20
Solution
b = 0.015 2 + 0.055 2 = 0.05701 m
As the brake lining angles relative to the

pivot, brake axis line, are not explicitly
shown on the diagram, they must be
calculated.
o
o
=
124
.
7
1 = 4.745
2
As 2>90o, the maximum value of sin is
sin90=1=(sin)max.
Mechanical Design
Solution cont.
Fa
DRUM
R68
For this brake with the

direction of rotation as
shown the right hand
shoe is selfenergising.
Fa
16
48
120
LINING
55
SHOE
15
Mechanical Design
20
Solution cont.
For the right hand shoe:
0.025 0.068 0.05701 1.2 106
Mn =
1
1
2
1
(124.7 4.745)
(sin249.4 sin9.49)
2
360
4
= 153.8 N m
Mechanical Design
Solution cont.
0.32 0.025 0.068 1.2 106
Mf =
1
0.05701
(cos249.4 cos9.49 )
0.068(cos4.745 cos124.7 ) +
4
= 57.1 N m
Mechanical Design
Solution cont.
a = 0.055 + 0.048 = 0.103 m
Mn M f 153 .8 57.1
Fa =
=
= 938 .9 N
a
0.103
The actuating force is 938.9 N.
Mechanical Design
Solution cont.
The torque applied by the right hand shoe
is given by
wr p max
(cos 1 cos 2 )
=
(sin )max
2
Tright shoe
0.32 0.025 0.0682 1.2 106

=
1
(cos4.745 cos124.7) = 69.54 N m
Mechanical Design
Solution cont.
The torque applied by the left hand shoe
cannot be determined until the maximum
operating pressure pmax for the left hand
shoe has been calculated.
Mechanical Design
Solution cont.
As the left hand shoe is self de-energising
the normal and frictional moments can be
determined.
'
'
M
p
153
.
8
p
max
Mn' = n max =
6
p max
1.2 10
'
max
Mf p
M =
p max
'
f
'
max
6
57.1p
=
1.2 10
Mechanical Design
Solution cont.
The left hand shoe is self de-energising,
so,
Mn + Mf
Fa =
a
Fa=938.9 N as calculated earlier.
938.9 =
153.8p
'
max
+ 57.1p
'
max
1.2 10 6 0.103
'
p max
= 0.5502 10 6 N / m 2
Mechanical Design
Solution cont.
The torque applied by the left hand shoe is
given by
2 '
wr p max
(cos 1 cos 2 )
Tleft shoe =
(sin )max
0.32 0.025 0.0682 0.5502 106
=
1
(cos4.745 cos124.7) = 31.89 N m
Mechanical Design
Solution cont.
The total torque applied by both shoes is:
Ttotal = Tright shoe + Tleft shoe =
69.54 + 31.89 = 101.4 N m
Mechanical Design
Comment
Fa
DRUM
R68
From this example the

advantage in torque
capacity of using selfenergising brakes is
apparent.
Both the left hand and the
right hand shoes could be
made self-energising by
inverting the left hand
shoe, having the pivot at
the top.
Fa
16
48
120
LINING
55
SHOE
Mechanical Design
15
20
Comment cont.
This would be advantageous if rotation
occurred in just one direction.
If, however, drum rotation is possible in
either direction, it may be more suitable to
have one brake self-energising for forward
motion and one self-energising for reverse
motion.
Mechanical Design
Band brakes
One of the simplest types
of braking device is the
band brake.
This consists of a flexible
metal band lined with a
frictional material
wrapped partly around a
drum.
The brake is actuated by
pulling the band against
the drum
r
F2
F1
Fa
Mechanical Design
Band brakes
For the clockwise
rotation shown the
friction forces
increase F1 relative to
F2.
r
F2
F1
Fa
a
c
Mechanical Design
Band brakes
The relationship between the tight and slack
sides of the band is given by
F1
= e
F2
F1 = tension in the tight side of the band (N),

F2 = tension in the slack side of the band (N),
= coefficient of friction,
= angle of wrap (rad).
Mechanical Design
Point of maximum contact pressure

The point of maximum contact pressure
for the friction material occurs at the tight
end and is given by:
F1
p max =
rw
where w is the width of the band (m).
Mechanical Design
Torque braking capacity

The torque braking capacity is given by
T = (F1 F2 )r
Mechanical Design
Moments
The relationship, for
the band brake shown
between the applied
lever force Fa and F2
can be found by
taking moments.
Fa c F2 a = 0
a
Fa = F2
c
r
F2
F1
Fa
a
c
Mechanical Design
Self-energising band brakes

The brake configuration
shown in the top figure
opposite is selfenergising for clockwise
rotation.
The level of selfenergisation can be
enhanced by using the
differential band brake
configuration shown in
the bottom figure
opposite.
r
F2
F1
Fa
a
c
F2
F1
b
Fa
a
c
Mechanical Design
Summation of the moments

Summation of the
moments about the
pivot gives
Fa c F2 a + F1b = 0
F2
F1
b
Fa
a
c
Mechanical Design
Force relationship
So the relationship between the applied
load Fa and the band brake tensions is
given by:
F a Fb
Fa =
Mechanical Design
Value of b
Note that the value of b must be less than
a so that applying the lever tightens F2
more than it loosens F1.
Substituting:
F2 a be
Fa =
c
Mechanical Design
Self-locking
The brake can be made self-locking if
a<be and the slightest touch on the lever
would cause the brake to grab or lock
abruptly.
This principle can be used to permit
rotation in one direction only as in hoist
and conveyor applications.
Mechanical Design
Example
Design a band brake to exert a braking
torque of 85 N m.
Assume the coefficient of friction for the
lining material is 0.25 and the maximum
permissible pressure is 0.345 MPa.
Mechanical Design
Solution
Propose a trial geometry, say r=150 mm,
=225o and w=50 mm.
F1 = p max rw = 0.345 10 6 0.15 0.05 = 2587 N
F1
2587 .5
F2 = = 0.25 (2252 / 360 ) = 969 N
e
e
T = (F1 F2 )r = (2587 .5 969 )0.15 = 242 .7 N m

Mechanical Design
Solution cont.
This torque is much greater than the 80 N
m desired, so try a different combination of
r, and w until a satisfactory design is
achieved.
Mechanical Design
Solution cont.
Try r=0.1 m, =225o and w=50 mm.
F1 = p max rw = 0.345 10 6 0.1 0.05 = 1725 N
F1
1725
F2 = = 0.25 (2252 / 360 ) = 646.3 N
e
e
T = (F1 F2 )r = (1725 646 .3 )0.1 = 107 .9 N m
Mechanical Design
Solution cont.
Try r=0.09 m, =225o and w=50 mm.
F1 = p max rw = 0.345 10 6 0.09 0.05 = 1552.5 N
F1
1552 .5
F2 = = 0.25 (2252 / 360 ) = 581.7 N
e
e
T = (F1 F2 )r = (1552 .5 581 .7 )0.09 = 87.4 N m
Mechanical Design
Solution cont.
The actuating force is given by Fa=F2a/c.
If a=0.08 m and c=0.15 m then,
0.08
Fa = 581.7
= 310.2 N
0.15
Mechanical Design
Conclusions
Clutches are designed to permit the smooth,
gradual engagement or disengagement of a
prime mover from a driven load.
Brakes are designed to decelerate a system.
Clutches and brakes are similar devices
providing frictional, magnetic or direct positive
connection between two components.
This section has concentrated on rotating
clutches and brakes and specifically on the
design of friction based devices.
Mechanical Design
Conclusions cont.
The detailed design of a clutch or braking
system involves integration of a wide range of
skills such as bearings, shafts, splines, teeth,
flywheels, casings, frictional surfaces,
hydraulics, sensors and control algorithms.
Both brakes and clutches can be purchased
from specialist suppliers or alternatively key
components such as brake pads or clutch discs
can be specified and bought in from specialist
suppliers and integrated into a fit for purpose
machine design.
Mechanical Design

Clutches and Brakes

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Clutches and Brakes

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Clutches and brakes

At the end of this section you should be able to

Typical applications for a clutch

Force, torque and energy

Mass moment of inertia

Mass moments of inertia

Clutch or brake location

Clutches must be designed principally to satisfy

Positive contact clutches

Ratchet and pawl clutch

Clutch selection criteria (Neale

One way clutch. Profiled elements jam against the outer

One way operation. e.g. backstop

One way clutch. Rollers ride up ramps and drive by

One way operation.

Embodies the mechanical principle of the wedge which

Contractors plant. Feed drives for

Single disc clutch

Used when diameter

Multiple disc clutch

The power transmitted can be increased by using more

Automatic engagement at a critical speed.

Electric motor drives.

Compact. Low wear.

Machine tool gearboxes. Numerical

Multiple disc clutch

OIL SUPPLY FOR

Running a clutch wet

Elemental annular ring

Note that F is also the necessary force

This equation represents the torque

Torque capacity with N faces

Dynamic friction coefficients, permissible

2p max rirdr = p max ri ro2 ri2

2Np max rirdr = p max Nri r ri

maximum torque for any outer

The procedure for determining the initial

Belt drive, small

From Table 10.3 taking mid range values

2 0.02497 1.55 106 (0.04324 0.02497) =

Belt drive, small

From Table 10.3 taking mid range values

1.55 10 (0.07325 0.04229) = 25500 N

So the clutch consists of a disc of inner and

Service factor Power

This must be an even number, so the

Comparative table of brake

Vehicles (rear axles

Vehicles (rear axles

where re is an effective radius.

The relationship between the average and

and assuming uniform wear by

Circular pad disk brake design

The maximum contact pressure is

Short and long shoe internal drum

Short shoe external drum brakes

Short shoe external drum brakes

Short shoe external drum brakes

Short shoe external drum brakes

Mpivot = aFa bFn + cFf = 0

Short shoe external drum brakes

Short shoe external drum brakes

Short shoe external drum brakes

Short shoe external drum brakes