Clutch

A clutch is a friction device which is used for connecting shafts. They are designed to
permit the connections and disconnection of two shafts while the driving shaft continues to be in
rotational motion.

Disc Clutch:
A single disk friction clutch is made up of two flanges one keyed rigidly to the driving
shaft and the other fitted to the driven shaft by a feather key or spline so that it may be moved
along the shaft.

Figure 1:

Analysis:

Figure 2:

Ro - outside radius of contact

Ri - inside radius of contact
 - cefficient of friction
p - pressure of contact between disks
F - axial force applied by the spring
T - torque to be transmitt ed
n F − number of pairs of friction surfaces
R F − friction radius

The normal force between th e disks is defined by the equation :

2 Ro 2 Ro
F=N=  pdA =   p r dr d ⎯
⎯→ 1
0 Ri 0 Ri

The torque that can be transmitt ed by friction is defined by the equation :

2 Ro
T =  N RF =    p r 2 dr d ⎯
⎯→ 2
0 Ri

1
Uniform Pressure Disk Clutch:

For new unworn clutches, the pressure distribution over the

surface of the disk is constant. Thus,

Equation (1) becomes;

2 Ro
F=P  r dr d
0 Ri

=P
r 2 Ro 2
2
 
Ri  0

(
F =  P Ro 2 − Ri 2 )
Equation (2) becomes;
F 2 Ro
T=
(
 Ro − Ri 2
2
) 
0 Ri
r 2 dr d

=
F
(
r3
 Ro 2 − Ri 2 3 )
  Ro
Ri
2
0

2 Ro 3 − Ri 3
T=F
3 Ro 2 − Ri 2

The torque equations may be written as:

2 Ro 3 − Ri 3
T =  F RF nF where : R F =
3 Ro 2 − Ri 2

Uniform Wear Clutch:

The condition of uniform pressure distribution is essentially correct for new contact
surfaces, but on account of relative motion between surfaces during the engaging period, there is
certain amount of wear, especially when lubrication is absent, as is usually the case for clutches
depending on friction for power transmission. In order that the surfaces will remain in contact, the
wear in the axial direction must be the same for all values of r. The amount of wear W is
proportional to the work done by friction, which is in turn proportional to the product of the
normal pressure and the velocity of rubbing as shown in figure 4.

Figure 4:
C - pressure constant; lb
in
2
K - wear constant; in
W = kpv = Kpr lb
k - wear constant; in − sec
2
W C
P= = lb
Kpr r
v - rubbing velocity; in
sec
W - axial wear of friction @ radius r; in.
r – radius at any differential element
analyzed

2
Equation (1);
2 Ro
F=C  
0 Ri
dr d

F = pr r Ri  0
Ro 2

F = pr (Ro - Ri )2
F
p=
2 (Ro - Ri )r

Equation (2) becomes;

F 2 Ro

2 (Ro - Ri ) 0 
T= r dr d
Ri

=
F r2
2 (Ro - Ri ) 2
 
Ro
Ri
2
0

 Ro + Ri 
T =  F 
 2 

The torque equation maybe rewritten as:

Ro + Ri
T =  F RF nF where : R F =
2

Cone Clutch:

The equations for the developed torque T and friction radius R F for disc clutches apply to
cone clutches with the exception that the pressure must be measured perpendicular to the cone
surface. After the clutch is engaged and for steady operation, the axial force Fa required to
produce a normal force Fn is:

Fa = Fn sin

The axial force needed to engage the cone when the cup is not rotating is:
Fe = Fn (sin +  cos )

3
Example 1:

An automobile engine develops its maximum brake torque at 2800 rpm when the brake
horsepower developed is 200. a design value of  = 0.25 is expected to be
reasonable for the asbestos facing and it is desired that the mean diameter of the clutch discs
should not exceed 215mm. The average permissible pressure between the disks is 345 kPa . The
driving disk is double faced. What should be the outside and inside diameters of the disks?

Figure:

Solution:

9550  hp  0.746  10 3 9550  200  0.746  10 3

T= = = 508,878.6 N - mm
n 1800
BASED ON UNIFORM WEAR :
 Ro + Ri 
T =  F n F Ro + Ri = 215mm, n F = 2pairs,  = 0.25
 2 
 215 
508,878.6N - mm = 0.25F 2
 2 
F = 9467.5N
For a maximum permissibl e pressure of 345 kPa.
F = p2 (Ro - Ri )Ri
9467.5 = 0.345 N  2 (Ro - Ri )Ri
mm
(Ro - Ri )Ri = 4367.54 mm 2 ⎯
⎯→ 1
The average diameter, Dm = Ro + Ri
Ro + Ri = 215 ⎯
⎯→ 2
Substitute Ro in eq. 2 and in eq. 1
Ri 2 - 107.5Ri + 2183.8 = 0
Thus; Ri = 80 mm Ro = 135 mm
Di = 160 mm Do = 270 mm

4
Example 2:

A gasoline engine driven tractor is equipped with a multiple disk clutch with 6 driven disks
faced with asbestos fabric whose coefficient of friction is 0.25. The annular area of contact
between the disks has an inside diameter of 8 in. and an outside diameter of 12 in. The
construction of the clutch is such that 5 helical springs provide the required force to transmit
power. Each of the 5 steel helical springs have an outside coil diameter of 1 ½ in., 7 coils with
squared and ground ends, made of W & M wire gage # 5. When the clutch is engaged, the springs
have a length of 2 ¾ in. when the clutch is disengaged the springs have a length of 2 ½ in. and the
force in the spring increased by 50%. What maximum horsepower can be transmitted by this
clutch at 1200 rpm?

Solution:
BASED ON UNIFORM WEAR :
 Ro + Ri 
T =  F  nF ; n F = 6 + 5 − 1 = 10 pairs
 2 
Ro + Ri 8 + 12
= = 5 in.
2 4
For the springs :
Dm = 1.5 - Dw W & M gage #5 : Dw = 0.207 in
Dm = 1.5 - 0.207
Dm = 1.293 in.
Dm 1.293
C= = = 6.25
Dw 0.207
F GDw
k= = For steel : G = 11.5  10 6 psi
 8C Nc
3

Nc = 7 - 2 = 5 coils
11.5  10 6  0.207 lbs
k= = 243.76
8  6.25  5 in.
when clutch is disengaged :  = 2.75 - 2.5 = 0.25 in.
lbs
additional load on each spring; F = k = 243.76  0.25 in.
in.
F = 60.95 lbs.
If P = force in each spring when clutch is engaged : P + F = 1.50P
60.95
P= = 121.88 lbs.
0.5
Axial force on the clutch, F = 5  121.88 = 609.4 lbs.
Thus : T = 0.25  609.4  5  10 = 7617.5 in. - lbs.
@ 1200 rpm :
7617.5  1200
HP =
63000
HP = 145 ⎯⎯→ ans.

5
Example 3:

A cone clutch for industrial use is to transmit 15hp @ 400 rpm. The mean diameter of the
clutch is 10 in. and the face angle  =10 degrees. Let  = 0.30 for the cast iron cup and the
asbestos lined coned and the permissible pressure is 35 psi. Compute (a) the axial force needed to
transmit power (b) the face width (effective) (c) the axial force needed to achieve engagement
under load.

Figure:

Solution:

63,000  15
T= = 2362.5 in - lbs.
400
 Ro + Ri   10 
a) T =  F  ; 2362.5 = 0.30F 
 sin   2 

 sin30  2 
F = 273.5 lbs. → ans.
b) FACE WIDTH :
 Ro + Ri 
F = p2 (Ro - Ri ) (
 = p Ro − Ri
2 2
)
 2 
273.5
Ro 2 − Ri 2 = =
  35
Ro 2 − Ri 2 = 2.487 in. 2 → 1
Ro + Ri = 10 → 2
Divide eq. 1 by eq. 2 :
Ro − Ri = 0.2487 → 3
Ro + Ri = 10 → 2
Ro = 5.124 in. ; Ro = 5.125 in.
Ri = 4.876 in. ; Ri = 4.875 in.
Ro - Ri 5.125 − 4.875
b= = = 1.439 in. ; use b = 1 1 2 in. → ans.
sin sin 10
c) Fe = Fn(sin +  cos )

Fe =
273.5
( )
sin 10 + 0.30 cos 10 = 738.8 lbs. → ans
sin10 