Machine Design II

Prof. M.M.Mayuram

MODULE III
Brakes, Clutches, Flywheel, Couplings
Brakes
A brake is a device by means of which artificial resistance is applied on to a
moving machine member in order to retard or stop the motion of the member or
machine

Types of Brakes
Different types of brakes are used in different applications
Based on the working principle used brakes can be classified as mechanical
brakes, hydraulic brakes, electrical (eddy current) magnetic and electro-magnetic
types.

Mechanical Brakes
Mechanical brakes are invariably based on the frictional resistance principles In
mechanical brakes artificial resistances created using frictional contact between the
moving member and a stationary member, to retard or stop the motion of the moving
member.

Design and Analysis

To design, select or analyze the performance of these devices knowledge on the
following are required.

The braking torque

The actuating force needed
The energy loss and temperature rise

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Machine Design II

At this beginning stage attention will be focused mainly on some preliminary

Prof. M.M.Mayuram

analysis

related to these aspects, namely torque, actuating force, energy absorbed and
temperature rise. Torque induced is related to the actuating force, the geometry of the
member and other contact conditions. Most mechanical brakes work on the frictional
contact basis and classified based on the geometry. The figure shows a brake shoe
mounted on a lever, hinged at O, having an actuating force Fa, applied at the end of the
lever. A normal force Fn is created when the shoe contacts the rotating drum.

Brakes Classification

Various shoe configurations are illustrated. Each consists of a body whose motion is
braked together with a shoe which can swing freely about a fixed hinge H. A lining is
attached to the shoe and contacts the braked body. The actuation force P applied to the
shoe gives rise to a normal pressure and corresponding braking friction distributed over
the area A of contact between lining and braked body, Shoes are classed as being
either short or long. A short shoe is one whose lining dimension in the direction of
motion is so small that contact pressure variation is negligible, i.e. the pressure is
uniform everywhere, at pm say.
When the area of contact becomes larger, the contact may no longer be with a uniform
pressure, in which case the shoe is termed as long shoe. The shoes are either rigid or
pivoted, pivoted shoes are also some times known as hinged shoes. Rigid shoe brakes
-rigid because the shoes with attached linings are rigidly connected to the pivoted posts.

Indian Institute of Technology Madras

Machine Design II

Prof. M.M.Mayuram

Basic Mechanism of Braking

The illustration below explains the working of brakes in more detail. An
element

dA of the lining is shown with the braked body moving past

at velocity v.

The

moment

of

the

frictional

contributes

to

the

retardation

mechanism

of

braking

is

force
of

illustrated

relative
motion
above.

to

the

and
Some

point

braking.
basic

of
The

motion
basic

concepts

of

braking are now highlighted using a short shoe analysis.

Preliminary Analysis
And a frictional force Ff of magnitude f.Fn, f being the coefficient of friction, develops
between the shoe and the drum develops. Since the shoe is short we assume the we
assume the pressure is uniformly distributed over the contact area. Consequently the
equivalent normal force Fn = p .A, where = p .A, where A is the surface area of the shoe.

Indian Institute of Technology Madras

Machine Design II

Prof. M.M.Mayuram

Rim Type Brakes Short Shoe Analysis

Applying the equilibrium condition by taking moment about the pivot O we can write
M O = Fa a Fn b + f Fn c = 0

Substituting for Fn and solving for the actuating force, we get,

The reaction forces on the hinge pin (pivot) are found from a summation of forces,
i.e.
The torque on the brake drum is then,
Fx = 0, R x = fpa A

F = 0, R = p A F
y
y
a
a

With the shown direction of the drum rotation (CCW), the moment of the frictional force f.
Fn c adds to the moment of the actuating force, .Fa Self- energizing.
As a consequence, the required actuation force needed to create a known contact
pressure p is much smaller than that if this effect is not present. This phenomenon of
frictional force aiding the brake actuation is referred to as self-energization.

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Machine Design II

Prof. M.M.Mayuram

Self- energizing
Leading and trailing shoe
For a given direction of rotation the shoe in which self energization is present is known
as the leading shoe
When the direction of rotation is changed, the moment of frictional force now will be
opposing the actuation force and hence greater magnitude of force is needed to create
the same contact pressure. The shoe on which this is prevailing is known as a trailing
shoe.

Leading and Trailing Shoe

At certain critical value of f.c the term (b-fc) becomes zero. i.e no actuation force need
to be applied for braking. This is the condition for self-locking. Self-locking will not occur
unless it is specifically desired.

Self Locking
Short and Long Shoe Analysis
Foregoing analysis is based on a constant contact pressure p.
In reality constant pressure may not prevail at all points of contact on the shoe.
In such case the following general procedure of analysis can be adopted

General Procedure of Analysis

Estimate or determine the distribution of pressure on the frictional surfaces
Find the relation between the maximum pressure and the pressure at any point
For the given geometry, apply the condition of static equilibrium to find the actuating
force, torque and reactions on support pins etc.

Indian Institute of Technology Madras

Machine Design II

Prof. M.M.Mayuram

Drum Brakes
Among the various types of devices to be studied, based on their practical use, the
discussion will be limited to Drum brakes of the following types which are mainly used
in automotive vehicles and cranes and elevators.

Drum Brake Types:

Rim types with internal expanding shoes
Rim types with external contracting shoes

Internal expanding Shoe

The rim type internal expanding shoe is widely used for braking systems in automotive
applications and is generally referred as internal shoe drum brake. The basic approach
applied for its analysis is known as (pivoted) long shoe brake analysis.

Long Shoe Analysis

In this analysis, the pressure at any In this analysis, the pressure at any point is
assumed to be proportional to point is assumed to be proportional to the vertical
distance from the hinge pin, the vertical distance from the hinge pin, which in this case
is proportional to which in this case is proportional to sine of the angle and thus, sine of
the angle and thus,
The normal force dN is computed as the product pressure and area and the frictional
force as the product of normal force and frictional coefficient i.e. f dN. By integrating
these over the shoe length in terms of its angle the braking torque T, actuating force F
and the pin reactions and are computed. Rx Ry
pa
p
=
sin sin a

or p = pa

sin
sin a

p bra 1
1

2 1 (sin 22 sin 21 )
MN = a

sin a 2
4

Mf =

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fpa br
sin a

2
2
r cos 1 cos 2 2 (sin 2 sin 1 )

Machine Design II

Prof. M.M.Mayuram

Ry =

A=
B=

pa br

sin a

(B fA) Fx

1
sin 2 2 sin 2 1
2

1 1
1

( ) sin 2 sin 2
2 2 2 1 4
2
1

The braking torque T on the drum by the shoe is of the frictional forces fDN times the
radius of the drum and resulting equation is the actuating force F is determined by the
summation of the moments of normal and frictional forces about the hinge pin and
equating it to zero. Depending on the direction of drum rotation,
F=

M N Mf
c

(-sign for self energizing) where,

MN and Mf are the moment of the normal and frictional forces respectively, about the
shoe pivot point.

Double Shoe Brakes

Note that our foregoing analysis is for a single shoe In most practical application the
brakes will contain two shoes symmetrically positioned around the brake drum as
shown earlier
If both the shoes are arranged such that both are leading shoes in which self
energizing are prevailing, then all the other parameters will remain same and the
total braking torque on the drum will be twice the value obtained in the analysis.
However in most practical applications the shoes are arranged such that one
will be leading and the other will be trailing for a given direction of drum rotation
If the direction of drum rotation changes then the leading shoe will become
trailing and vice versa.
Thus this type of arrangement will be equally effective for either direction of
drum rotation.

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Machine Design II

AUTOMOTIVE DRUM BRAKES

Indian Institute of Technology Madras

Prof. M.M.Mayuram

Machine Design II

Indian Institute of Technology Madras

Prof. M.M.Mayuram

Machine Design II

Indian Institute of Technology Madras

Prof. M.M.Mayuram

Machine Design II

Prof. M.M.Mayuram

However the total braking torque will not be the twice the value of a single shoe.
This is because the effective normal pressure (force) on the trailing shoe will not
be the same, as the moment of the friction force opposes the normal force, there
by reducing its actual value though in most applications the same normal force is
applied or created at the point of force application on the brake shoe.
Consequently we may write the actual or effective pressure prevailing on a
trailing shoe

F.a
p'a = pa .

(M n + M f )

Resulting torque
p
TB = f .w.r 2 . a (cos q1 - cos q 2 )(pa + pa ')
sin q a

External Contracting Shoe

The same analysis can be extended to a drum brake with external contracting type of
shoes, typically used in elevators and cranes.

Indian Institute of Technology Madras

Machine Design II

Prof. M.M.Mayuram

Corresponding contact geometry is shown in the figure. The resulting equations for
moment of normal and frictional force as well as the actuating force and braking torque
are same as seen earlier. For convenience they are reproduced here again

fbp r 2 cos cos

a
1
2
T=
sin
a

F=

M N Mf
c

p bra 1
1

MN = a
2 1 (sin 22 sin 21 )

sin a 2
4

Mf =

2
2
r cos 1 cos 2 2 (sin 2 sin 1 )

fpa br
sin a

Pivoted block brake with Long shoe

Twin Shoe Brakes
Behavior
shoes
used

of

are
to

single

shoe

combined
minimize

into
the

has
a

been

discussed

complete

unbalanced

practical

forces

on

the

lever,

at
brake
the

length.
unit,
drum,

Two

such

two

being

shaft

and

bearings.

Brake with long Pivoted Shoe

When

the

frictional

shoe

force

is

(f.Fn)

rigidly
is

to

fixed

to

unseat

the

block

with

the

tendency

respect

to

the

of

the
lever.

This is eliminated in the case of pivoted or hinged shoe brake and it

also provides some additional advantages.

Long Hinged Shoe

This is a

hinged shoe brake - the shoes are hinged to the posts. The

hinged shoe is connected to the actuating post by the hinge, G, which

introduces

another

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degree

of

freedom

so

the

shoe

tends

to

assume

Machine Design II

an

Prof. M.M.Mayuram

optimum

position

in

which

the

pressure

distribution

over

it

is

less

peaked than in a rigid shoe.

As

wear

conform
shoes.

proceeds
more

This

the

closely
permits

extra
to
the

the

degree

of

freedom

drum

than

would

linings

to

act

allows
be

more

the

the

linings

case

effectively

to

to

rigid

and

also

reduces the need for wear adjustment.

The

extra

grounds

of

expense
more

of

providing

uniform

lining

another
wear

hinge
and

is

thus

consequently

justified
a

on

the

longer

life.

This is the main advantage of the pivoted shoe brake

This is possible only if the shoe is in equilibrium.
For

equilibrium

of

the

MG=T+Fxby-Fybx=0 where bx
by

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shoe:
= b.cos G
= b.sinG

Machine Design II

Prof. M.M.Mayuram

This

needs

that

the

resultant

moment

due

to

the

frictional

force

(and

due to the normal force) about the pivot point should be zero, so that
no rotation of the shoe will occur about the pivot point.
The actuating force P is applied to the post HG so the shoe itself is
subject to two contacts only - the (ideal) at pin G and the distributed
contact with the drum.
To facilitate this location of the pivot is to be selected carefully.
The location is in such a way that the moment of frictional force (and
the

normal

force)

about

the

pivot

is

zero.

i.e

the

actual

distributed

contact leads to the ideal contact at the hinge or pivot to facilitate this
the location of the pivot is to be selected carefully. The location is in
such

way

that

the

moment

of

frictional

force

(and

the

normal

force)

about the pivot is zero.

i.e the actual distributed contact leads to the ideal contact at the hinge
or pivot Further it is desirable to minimize the effect of pin reaction for
which the shoe pivot and post pivot points are made con current.
Let us now look how this can be met and satisfying the conditions set
above

and

consequently

the

derive

the

equations

relating

the

location

of the pivot from the center of the drum

In
The

the

previous

angle

of

section,
contact

block

between

brake

the

with

block

and

short

shoe

was

discussed.

the

brake

drum

in

such

cases is usually small and less than 45o. It is therefore, reasonable to

assume

that

the

concentrated
applicable

at

for

normal

the

the

reaction

midpoint

brake

with

(N)

of

the

the

long

and
shoe.
shoe.

frictional
This
When

( N )

force

assumption
the

block

is
is

are
not
rigidly

fixed to the lever, the tendency of the frictional force ( N ) is to unseat

the block with respect to the lever as shown in the figure.
the

pivoted

In case of

shoe brake, the location of the pivoted can be selected in

such as way that the moment of frictional force about the pivot is zero.

Indian Institute of Technology Madras

Machine Design II

Prof. M.M.Mayuram

This is the main advantage of the pivoted shoe brake.

A double block

brake with two symmetrical and pivoted shoes is show in figure.

An

element

an angle
where

of

the

brake drum.

lining

located

width

of

the

at

an

angle

and

subtending

The area if the element is ( Rdw ) ,

is shown in figure.

is

friction

friction

lining

parallel

to

the

axis

of

the

If the intensity of pressure at the element is p, the normal

reaction dN on the element is given by

dN = (Rdw)p

Distribution of pressure
If the shoe is long then the pressure will not be uniform
We

need

pressure

to

determine

distribution

the

distribution

should

be

of

pressure

conducive

for

along

the

maintaining

lining;
a

the

uniform

wear, Since the brake drum is made of a hard material like cast iron or
steel,
shoe.

the

wear

occurs

on

the

friction

lining,

which

is

attached

to

the

As shown in fig the lining will retain the cylindrical shape of the

brake drum when wear occurs.

After the radial wear has take place, a

point such as X moves to X in order to maintain contact on the lining

with the brake drum.
is

the

wear

constrained

to

in

the
move

In figure x is the wear in the X direction and r

radial

direction.

towards

the

If

brake

it

is

assumed

drum

to

that

the

compensate

shoe
to

is

wear,

x should be constant because it is same for all points. Therefore,

x =

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r
= constant
cos

(b)

Machine Design II

The

Prof. M.M.Mayuram

radial

wear

force.

The

frictional

force

work
( dN )

is

proportional

done
and

by
the

the

to

the

work

frictional
rubbing

done

force

velocity.

by

depends
Since

the

frictional

upon
the

the

rubbing

velocity is constant for all points on friction lining,

r dN
Or r ( Rdwp )

Therefore

r p

(c)

From the expression (b) and (c)

p
= cons tan t or p = C1 cos
cos

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(d)

Machine Design II

Prof. M.M.Mayuram

Where C1

is

the

constant

of

proportionality.

The

pressure

is

maximum

when = 0 .
Substituting,

(e)

p max = C1
From Eqs (d) and (e),

p = pmax cos

Substituting this value in Eq. (a

(f)

dN = (Rdw)p max cos

The

forces

acting

on

the

element

of

the

friction

lining

are

shown

in

Figure. The distance h of the pivot is selected in such a manner that

the moment of frictional force about it is zero.
Therefore,

M f = fdN(h cos R) = 0

Substituting dN from Eq. (f),

( h cos

R cos d = 0

or

1 + cos 2
h
d R cos d = 0
2

0
0

or

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+
sin 2

2
h
R ( sin )0 = 0
2

0
4R sin
h=
2 + sin 2

Machine Design II

The

Prof. M.M.Mayuram

elemental

torque

of

frictional

N about

force

the

axis

of

brake

drum is dNR . Therefore

M t = 2 dNR
0

Substituting the value of dN from Eq.(f)

M t = 2R wp max cos d
2

M t = 2R wp max sin
2

The reaction R X can be determined by considering two components

( dN cos )

and ( dN sin ) .

Due to symmetry,

dN sin = 0
Therefore,

R x = 2 dN cos
0

= 2Rwp max cos 2 d

0

2 + sin 2
= 2Rwp max

1
or R x = Rwp max (2 + sin 2)
2
The

reaction

( dN sin )

Ry

can

be

and ( dN cos )

Due to symmetry,

dN sin

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determined

by

considering

two

components

Machine Design II

Prof. M.M.Mayuram

Therefore,

R y = 2 dN cos
0

= 2Rwp max cos 2 d

0

Pivoted

shoe

applications

brakes

are

1
Rwp max (2 + sin 2)
2

or

Ry =

are

mainly

limited

because

used
of

the

in

hoists
physical

and

cranes.

problem

in

Their
locating

pivot so close to the drum surface.

Energy Consideration
Kinetic energy is absorbed during slippage of either a clutch or brake, and this energy
appears as heat.

If the heat generated is faster than it is dissipated, then the

temperature rises.
The capacity of a clutch or brake is therefore limited by two factors:
1. The characteristics of the material and,
2. The ability of the clutch/brake to dissipate heat.

Energy to be Absorbed
If t is the time of brake application and av the average angular velocity

then

the energy to be absorbed in braking E

E = T. av.t
If a constant deceleration is assumed the av = /2 as 1= and 2 = 0

Temperature Rise
The temperature rise of the clutch or the temperature rise of the clutch or brake
assembly can be approximated brake assembly can be approximated by the classic
expression, by the classic expression,

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Machine Design II

Prof. M.M.Mayuram

. = E T Cm
Where is temperature rise in ,C is the specific heat of the brake drum material - 500J/Kg
for steel or Cast Iron m is the mass (kg) of the brake parts dissipating the heat into the
surroundings T C
A brake or clutch friction material should have the following characteristics to a degree,
which is dependent upon the severity of the service.
A high and uniform coefficient of friction.
Imperviousness to environmental conditions, such as moisture.

Frictional Material
The ability to withstand high temperatures together with good thermal conductivity.
Good resiliency.
High resistance to wear, scoring, and galling.
An improved lining material is being tried on an existing passenger car drum brake
shown in Figure. Quality tests on the material indicated permissible pressure of1.0 MPa
and friction co-efficient of 0.32. Determine what maximum actuating force can be
applied for a lining width of 40 mm and the corresponding braking torque that
could be developed.

Linings
The choice of lining material for a given application is based upon criteria such as the
expected coefficient of friction; fade resistance, wear resistance, ease of attachment,
rigidity or formability, cost, abrasive tendencies on drum, etc. The lining is sacrificial - it
is worn away. The necessary thickness of the lining is therefore dictated by the volume
of material lost - this in turn is the product of the total energy dissipated by the lining
throughout its life, and the specific wear rate

Rw (volume sacrificed per unit energy

dissipated) which is a material property and strongly temperature dependent.

The

characteristics of Ferodo AM 2, typical moulded asbestos, are illustrated. The coefficient

of friction, which may be taken as 0.39 for design purposes, is not much affected by

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Machine Design II

Prof. M.M.Mayuram

pressure or by velocity - which should not exceed 18 m/s. The maximum allowable
temperature is 400C.

Linings traditionally were made from asbestos fibers bound in an organic matrix,
however the health risks posed by asbestos have led to the decline of its use. Nonasbestos linings generally consist of three components - metal fibers for strength,
modifiers to improve heat conduction, and a phenolic matrix to bind everything together.

Brake Design Section

The braked system is first examined to find out the required brake capacity that is the
torque and average power developed over the braking period.

The brake is then

either selected from a commercially available range or designed from scratch ff a drum
brake has to be designed for a particular system (rather than chosen from an available
range) then the salient brake dimensions may be estimated from the necessary lining
area, A, together with a drum diameter- to- lining width ratio somewhere between 3:1
and 10:1, and an angular extent of 100 C say for each of the two shoes.

Indian Institute of Technology Madras

Machine Design II

Prof. M.M.Mayuram

Worked out Example

An improved lining material is being tried on an existing passenger car drum brake
shown in Figure. Quality tests on the material indicated permissible pressure of 1.0 MPa
and friction co-efficient of 0.32.

Determine what maximum actuating force can be

applied for a lining width of 40 mm and the corresponding braking torque that could be
developed. While cruising on level road at 100 kmph, if it is to decelerated at 0.5g and
brought to rest, how much energy is absorbed and what is the expected stopping
distance?
While cruising on level road at 100 kmph, if it is to decelerated at 0.5g and brought to
rest, how much energy is absorbed and what is the expected stopping distance?

Analysis based on leading shoe

p brd 2 1 1

Mn = a
(sin 22 sin 21 )

sin a 2
4

106 *40*10-3 *125 *103 * 0.1 115 1

( sin 240 sin10 )

*

1
2 180 4

=40*125*0.1 1.003- ( 1.03)

4

M n = 631.459 N.m

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Machine Design II

Prof. M.M.Mayuram

Pa

= 1 MPa

= 0.32

= 40 mm

max = 90

a = 187.5 mm
d = 1002 +86.12
= 99.99 100mm
r =125 mm

1 = 5 2 = 120

Mf =

f .b.rpm
d

r(cos 1 - cos 2 ) - sin 2 2 - sin 2 1

sin a
2

= 0.32 * 40 *10-3 *125 *10-3 *106 0.125(cos 5 - cos120) - 0.04(sin 2 120 - sin 2 5)

M f = 224.85 N - m

F*a= M N M f
F=

M n M f 631.459 224.85
=
=
a
0.187

2174.3N

 

Max. actutating force

p
F

2
a
a
T = fbr
cos cos ) 1 + M + M

sin

B
1
2

a
n
f

406.609
T = 0.32 * 40 *103 * (0.125)2 *106 (Cos5 Cos120) 1 +
856.36

B
T = 441.329 N-m
B
Running at 100 kmph

=100*5/8
= 27.7 m/s
U= 27.7 m/s

Deceleration =0.5*9.8=4.9
V 2 U 2 = 2aS
0 (27.7) 2 = 2 * (4.9) *S
S=

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27.7 2
= 78.29 m
2 * 4.9

Machine Design II

Prof. M.M.Mayuram

E = T.av .t
1 27.7 78.24
= 441.329
.

2 0.125 27.7
= 138206
= 138.2KJ

Clutch
Clutch Introduction
A Clutch is ia machine member used to connect the driving shaft to a driven shaft, so
that the driven shaft may be started or stopped at will, without stopping the driving shaft.
A clutch thus provides an interruptible connection between two rotating shafts
Clutches allow a high inertia load to be stated with a small power.
A popularly known application of Clutch is in automotive vehicles where it is used to
connect the engine and the gear box. Here the clutch enables to crank and start the
engine disengaging the transmission Disengage the transmission and change the gear
to alter the torque on the wheels. Clutches are also used extensively in production
machinery of all types.

Mechanical Model
Two inertias and traveling at the respective angular velocities and

one of which may

be zero, are to be brought to the same speed by engaging. Slippage occurs because
the two elements are running at different speeds and energy is dissipated during
actuation, resulting in temperature rise.
To analyze the performance of these devices the following are required.
1. The torque transmitted
2. The actuating force.
3. The energy loss
4. The temperature rise

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Machine Design II

Prof. M.M.Mayuram

As in brakes a wide range of clutches are in use wherein they vary in their are in use
their working principle as well the method working principle of actuation and application
of normal of actuation and application of normal forces. The discussion here will be
limited to mechanical type friction clutches or more specifically to the plate or disc
clutches also known as axial clutches

Frictional Contact axial or Disk Clutches

An axial clutch is one in which the mating frictional members are moved in direction
parallel to the shaft.

Single Dry plate Clutch

The torque that can be transmitted by a clutch is a function of its geometry and the
magnitude of the actuating force applied as well the condition of contact prevailing
between the members together with a uniform pressure all over its contact area and the
consequent analysis is based on uniform pressure condition.

Indian Institute of Technology Madras

Machine Design II

Prof. M.M.Mayuram

Uniform Pressure and wear

However as the time progresses some wear takes place between the contacting
members and this may alter or vary the contact pressure appropriately and uniform
pressure condition may no longer prevail. Hence the analysis here is based on uniform
wear condition

Elementary Analysis
Assuming uniform pressure and considering an elemental area of

dF = 2prdr
The normal force on this elemental area is
r0
F = 2prdr = p(r02 ri2 )
ri

The frictional force on this area is therefore

ro
ro
r

F = 2prdr = 2 p max i rdr = 2i p max (r0 ri )

r

ri
ri

Now the torque that can be transmitted by this elemental are is equal to the frictional
force times the moment arm frictional force times the moment arm about the axis that is
the radius r
The total torque that could be transmitted is obtained by integrating this equation
between the limits of inner radius ri to the outer radius ro

Indian Institute of Technology Madras

Machine Design II

Prof. M.M.Mayuram

ro
2
T = 2pr 2 dr = p(ro3 ri3 )
3
ri
Integrating the normal force between the same limits we get the actuating force that
need to be applied to transmit this torque.

Uniform Wear Condition

According to some established theories the wear in a mechanical system is proportional
to the PV factor where P refers the contact pressure and V the sliding velocity. Based
on this for the case of a plate clutch we can write

ri
r

p.r = constant for wear to be constant

Hence pressure at any point in the contact required

p=p

r
r
i

max

In the previous equations substituting this value for the pressure term p and integrating
between the limits as done earlier we get the equation for the torque is transmitted and
the actuating force to be transmitted and the actuating force to be applied. The clutch
used in automotive applications is generally a single plate dry clutch. In this type the
clutch plate is interposed between the flywheel surface of the engine and pressure plate.

Single Clutch and Multiple Disk Clutch

The clutch used in automotive applications is generally a single plate dry clutch
In this type the clutch plate is interposed between the fly wheel surface of the engine
and pressure plate. As both side surfaces of the clutch plate is used for transmitting the
torque, a term z is added to include the number of surfaces used for transmitting the
torque
The pressure plate is also used to apply the actuating force supplied from a series of
helical compression spring placed around the periphery of the plate or a single plate
type of spring.

Indian Institute of Technology Madras

Machine Design II

Prof. M.M.Mayuram

By rearranging the terms the equations can be modified and a more general form of the
equation can be written as

T = Z.f .Fa .R m
T is the torque (Nm). Z is the number of frictional disks in

contact.

f is the coefficient of friction

is the actuating force (N).
is the mean or equivalent radius (m).
Values of the actuating force F and the mean radius rm for the two conditions of
analysis are summarized and shown in the table

Indian Institute of Technology Madras

Machine Design II

Prof. M.M.Mayuram

Flywheel
A

flywheel

energy
when
it

is

and
the

during

an

serves

supply
the

inertial
as

of

energy-storage

energy

period

when

device.

reservoir,

storing

is

than

the

more

absorbs

energy

the

requirement

It

of

during

the

requirement
energy

is

mechanical

and

more

period
releases

than

the

supply.

Flywheels-Function need and Operation

The main function of a fly wheel is to smoothen out variations in the
speed

of

shaft

caused

by

torque

fluctuations.

If

the

source

of

the

driving torque or load torque is fluctuating in nature, then a flywheel is

usually

called

torque

time

engines

with

compressors,
absorbs
delivers

for.

function
one
punch

mechanical
the

Many

stored

loads need flywheels

Indian Institute of Technology Madras

machines

to
or

vary
two

over

energy

rock
by

by

load

the

cylinders

presses,

energy

have

cycle.

are

crushers
increasing

decreasing

patterns

its

that

Internal
typical

etc.
its

cause

have

angular

velocity.

combustion

example.

that

And

the

Piston
Flywheel

velocity
time

and

varying

Machine Design II

Prof. M.M.Mayuram

Design Approach
There are two stages to the design of a flywheel.
First,

the

smoothening

amount
must

of
b

energy

found

and

required

for

the

(mass)

be

defined

the

desired

moment

of

degree

of

inertia

needed

caters

the

required

and

safe

to absorb that energy determined.

Then
moment

flywheel
of

geometry

inertia

in

must

reasonably

sized

that

package

is

against

failure at the designed speeds of operation.

Small fly wheels are solid discs of hollow circular cross section.

As the energy requirements and size of the flywheel increases the geometry changes to
disc of central hub and peripheral rim connected by webs and to hollow wheels with
multiple arms.

Indian Institute of Technology Madras

Machine Design II

Prof. M.M.Mayuram

Design Parameters
Flywheel

inertia

(size)

needed

directly

depends

upon

the

acceptable

changes in the speed.

The

change

in

the

shaft

speed

during

cycle

is

called

the

dividing

it

speed

fluctuation and is equal to max- min

We

can

normalize

this

to

dimensionless

average or nominal shaft speed (ave) desired.

Fl = max min

Indian Institute of Technology Madras

ratio

by

by

the

Machine Design II

Prof. M.M.Mayuram

Speed Speculation
This ratio is termed as coefficient of speed fluctuation Cf and it is defined as

min
Cf = max

Where

is

nominal

angular

nominal

shaft

speed

(ave)

velocity.

This

coefficient

is

velocity,
desired.

design

given
where

by,

by

the

avg

is

nominal

angular

be

chosen

by

parameter

to

average

or

the

designer.

Coefficient of Speed Speculation

The smaller this chosen value, the larger the flywheel have to be and
more

the

cost

and

weight

to

be

added

to

the

system.

However

the

smaller this value more smoother the operation of the device

It

is

typically

machinery

set

and

to

as

value

high

as

between
0.20

0.01

for

to

0.05

applications

for

precision

like

crusher

hammering machinery.

Design Equation
The kinetic energy Ek in a rotating system
=
Hence

the

change

in

( )

1
I 2
2

kinetic

energy

of

system

hammering machinery.

EK =

1
Im 2 max 2min
2
E K = E 2 E1

avg =

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( max + min )
2

can

be

given

as,

Machine Design II

Prof. M.M.Mayuram

1
I 2avg
2 s
E 2 E1 = Cf I2
Ek
Is =
2
Cf avg

EK =

The
I

above

equation

corresponding

to

can
the

be

used

known

)( Cf avg )

to

obtain

energy

appropriate

change

Ek

for

Ek

obtained

flywheel

specific

inertia
value

coefficient of speed fluctuation Cf,

Torque Variation and Energy

The

required

change

in

kinetic

energy

is

from

the

known

torque time relation or curve by integrating it for one cycle.

@ max
Tl Tavg d = E K

@ min

The

mass

moment

of

inertia

needed

in

the

order to obtain selected coefficient of fluctuation.

EK =
Is =

Indian Institute of Technology Madras

1
I 2avg
2 s
Ek

2
Cf avg

)( Cf avg )

entire

rotating

system

in

Machine Design II

Prof. M.M.Mayuram

Torque Time Relation without Flywheel

Torque Time Relation without Flywheel

Indian Institute of Technology Madras

Machine Design II

Prof. M.M.Mayuram

Geometry of Flywheel
The geometry of a flywheel may be as simple as a cylindrical disc of
solid

material,

or

may

be

of

spoked

construction

like

conventional

wheels with a hub and rim connected by spokes or arms

The

latter

arrangement

is

more

efficient

of

material

especially

for

large flywheels, as it concentrates the bulk of its mass in the rim which
is

at

the

largest

radius.

Mass

at

largest

radius

contributes

much

more

since the mass moment of inertia is proportional to mr2

For

solid

disc

geometry

with

inside

radius

, the mass moment of inertia I is

Im = mk 2 =

Indian Institute of Technology Madras

m 2 2
(r + r )
2 o i

ri

and

out

side

radius ro

Machine Design II

Prof. M.M.Mayuram

The mass of a hollow circular disc of constant thickness t is

m=

= ro2 ri2 t
g
g

Combing the two equations we can write

Im =

Where is

material

weight

geometric

proportions

i.e

density
by

4 4
r r t
2g o i

The

assuming

equation
inside

to

is

better

out

side

solved
radius

by
ratio

and radius to thickness ratio.

Stresses in Flywheel
Flywheel

being

rotating

distributed

mass

and

attempts

disc,
to

centrifugal
pull

it

apart.

stresses
Its

acts

effect

is

upon

its

similar

to

those caused by an internally pressurized cylinder

Analogous

to

t =

2 3 + v 2 2 1 + 3v 2

r
ri + ro
g
3+ v
8

r =

2 3 + v 2 2 ri2 ro2
2

ri + ro 2 r
g
8
r

thick

cylinder

under

internal

pressure

the

tangential

and radial stress in a solid disc flywheel as a function of its radius r is

given by

Indian Institute of Technology Madras

Machine Design II

Prof. M.M.Mayuram

:
The

point

of

most

maximum.

What

stress

at

that

fragments

can

Since

forces

speed
which

the
also,

causes
point

failure

from

explode

the

inside

in

where

the

of

flywheel

for

where

is

are

the

typically

originated

extremely

stresses

checking

radius

fracture

resulting

causing

instead

is

and

stress
the

is

tangential

upon

fracture

dangerous

consequences,

function

the

stresses,

the

of

maximum

rotational
speed

at

the stresses reach the critical value can be determined and safe

operating
factor.

interest

speed

can

Generally

some

be

calculated

means

to

or

specified

preclude

its

speed is desirable, for example like a governor.

Consequently

F.O.S (N) = Nos =

yield

Indian Institute of Technology Madras

based
operation

on

beyond

safety
this