Prepared by: Cem Baykal Cross-section of the key is as:

Room: B-175 Phone: 5256

E-mail: baycem@metu.edu.tr
The proportions of the rigid sleeve made of cast iron
𝑡 = 10 𝑚𝑚 are given as:
ME 308 – MACHINE ELEMENTS II 𝑑 = 2𝑑 + 12.5 𝑚𝑚, 𝐿 = 3.5𝑑, 𝐷 = 80𝑚𝑚.
TUTORIAL 7
COUPLINGS, BRAKES & CLUTCHES 𝑤 = 16 𝑚𝑚
Take the length of each key as 5𝐿/11.
NOTE: Equations are taken from “Shigley’s Mechanical Engineering Design 10th
Solution
edition”, Richard G. Budynas, J. Keith Nisbett.
Operating speed of the shaft is; 𝜔 = 350 ⋅ (2𝜋/60) = 36.65
1) Analyze the rigid sleeve coupling that transmits 40 kW at a speed of 350 rpm. The Transmitted torque is found as; 𝑃 = 𝑇𝜔 → 𝑇 = 40𝑘𝑊/(36.65 ) = 1091.35 𝑁𝑚
coupling is shown in the sketch below. Considering the overload factor, the maximum torque on the shaft is;
𝑇 = 𝑇 ∙ 1.25 = 1364.19 𝑁𝑚
Given geometrical parameters are;
𝑑 = 2𝑑 + 12.5 𝑚𝑚 = 117 𝑚𝑚, 𝐿 = 3.5𝑑 = 182 𝑚𝑚
The maximum shear stress on the rigid sleeve is;
𝐷
𝑇𝑟 𝑇
𝜏 = = 𝜋 2 = 16.52 𝑀𝑃𝑎
,
𝐽 (𝐷 − 𝑑 )
32
The rigid sleeve coupling is The allowable stress is 40 MPa; hence the sleeve is safe. Shear stress in the key is
used for joining two shafts, and calculated as;
𝑇
the coupling is required to
𝑑
transmit 25% overload. The 𝐹
𝜏 = = 2 = 39.64 𝑀𝑃𝑎
material of the key and the shaft 𝐴 5𝐿
𝑤
is the same, and the coupling is 11
made of cast iron. Allowable The allowable shear stress is 50 MPa. The bearing stress induced in the key:
𝑇
shear stresses for the cast iron 𝑑
and the shaft material are 40 MPa and 50 MPa, respectively. 𝐹
𝜎 , = = 2 = 126.85 𝑀𝑃𝑎
𝐴 𝑡 5𝐿
The width of the key is 16 mm, and the thickness is 10 mm, and the diameter of the 2 11
The allowable bearing stress of the key is 140 MPa; hence the key is also safe.
shaft is 52 mm. The bearing strength of the shaft material is 130 MPa, and the cast iron
is 140 MPa.
2) For the design of the band brake shown in the figure below, determine: Considering impending motion at contact surfaces, write force and moment balances:
a) The brake torque
𝐹 = 𝑁 cos(60 ) − 0.1𝑁 cos(30 ) − 𝑁 cos(60 ) − 0.1𝑁 cos(30 ) = 0
b) The maximum actuating force that can be applied to the lever, which is pivoted about
point O. 𝐹 = 𝑁 sin(60 ) + 0.1𝑁 sin(30 ) + 𝑁 sin(60 ) − 0.1𝑁 sin(30 ) − 𝑃 − 𝑃
c) Self-locking characteristics of the brake. =0
(Neglect the weights of the components) Solving force equilibrium equations yields: 𝑁 = 5592𝑁, 𝑁 = 3941𝑁.
Moment equilibrium is:

𝑀 = 𝑇 − (𝑃 − 𝑃 )𝑟 − 0.1(𝑁 + 𝑁 )𝑟 = 0
300 mm
𝑇 Total brake capacity is: 𝑇 = 1385 Nm
b) Free body diagram of the actuating lever is:

350 𝑚𝑚

The coefficients of friction between the band and the pipe and the pipe and the block
are 0.30 and 0.10, respectively. The band can withstand a maximum of 1MPa of
pressure. The width of the band (𝑏) and outer radius of the pipe (𝑟) are 20 mm and 300
mm, respectively.
Moment equilibrium about the pivot point, O, of the lever gives force required:
Solution ∑𝑀 = 𝑃 ∙ 70.71𝑚𝑚 − 𝑃 ∙ (350 + 70.71)𝑚𝑚 = 0
Maximum actuating force is: 𝑃 = 1008.44 N
a)
According to the direction of rotation, more c) This band-type brake is not self-locking. The condition of being self-locking is such
significant force and maximum pressure 𝑝 occurs at that force required to actuate braking is smaller than or equal to zero (𝐹 0). However,
point A’. in our case, there is always a need for actuating force to start braking action, which is
From eq. 16-21: at most 1008 N.
𝑃 = 𝑝 𝑏𝑟 = (1𝑀𝑝𝑎)(20𝑚𝑚)(300𝑚𝑚)
= 6000𝑁
The angle of the wrap, 𝛼 = 180° = 𝜋 𝑟𝑎𝑑. From eq.
16-19:
𝑃 6000𝑁
𝑃 = = = 2338𝑁
𝑒 𝑒 .
3) For the double running shoe external drum brake shown in the figure, determine the From force equilibriums for the L bar:
maximum force that can be applied on the lever. The maximum permissible pressure
on the brake lining is 1.8 MPa. Also, determine the torque capacity of the brake. The 𝐹 =𝐹 −𝐹 =0→𝐹 =𝐹 = 3𝐹
rotation is given as clockwise. 𝐹 =𝐹 −𝐹 =0→𝐹 =𝐹
Design parameters of the brake mechanism are:
After finding the forces acting on the shoes, it is now possible to pass to the analysis of
The face width of the shoes, 𝑏 = 40𝑚𝑚
Coefficient of friction between the drum and the shoes, 𝑓 = 0.3 the brake mechanism — the below figure used to represent shoes separately and to ease
Radius, 𝑟 = 100𝑚𝑚 the calculations.

Solution
As a first notice, the left-hand shoe in this brake is self-energizing, while the right-hand
shoe is not self-energizing (for the given rotation direction). Because of its self-
energizing effect, the torque capacity of the left-hand shoe is expected to be higher.
However, there is a need to investigate the moment arms of both shoes. The shoes do
not have the same moment arm; also, they do not have the same brake force. The force
on the lever arm distributes unevenly between the shoes.
From the moment equilibrium on the pin at G (pin of L bar):
𝑀 = 𝐹(150) − 𝐹 (50) = 0 → 𝐹 = 3𝐹 = 𝐹
In the above figure, it can be seen that left-hand shoe is self-energizing, but the right-
hand shoe is not. Notice that the pins where the “R” forces are applied correspond to
the hinged ends of the shoes.
The left-hand shoe is considered firstly as the maximum pressure applied to it. The
explanation of this fact comes from the self-energizing property of the left-hand shoe.
For left-hand shoe, the frictional moment, 𝑀 , has a decreasing effect on the moment
of normal forces, 𝑀 . It maximizes the normal force on the shoe, thus maximizing the Moment equilibrium around the hinge:
pressure. However, if the right-hand shoe is considered, the maximum possible 𝑀 is 𝑀 = −𝑀 − 𝑀 − 𝐹 ⋅ (40𝑚𝑚 − 15𝑚𝑚) + 𝐹 ⋅ (120𝑚𝑚 + 115𝑚𝑚) = 0
limited by 𝑀 . So, the lever force is considered concerning the left-hand shoe’s torque
→ 𝑝 = 0.8327 𝑀𝑃𝑎
capacity, and then the torque capacity of the right-hand shoe is considered. The shoes Torque capacity of the right-hand shoe from eqn.16-6 is:
in this brake mechanism have the same geometrical parameters. The only difference 𝑓𝑝 𝑏𝑟 (cos(𝜃 ) − cos(𝜃 ))
𝑇 = = 177.0811 𝑁𝑚
between them is the direction of 𝑀 . So, 𝑀 and 𝑀 are found for the left-hand shoe, sin(𝜃 )
and the same values are applied to the right-hand shoe. So, the braking capacity of the mechanism is:
𝑇 = 𝑇 + 𝑇 = 559.8718 𝑁𝑚
For the left-hand shoe:
When looked at the detailed figure, it is seen that the left-hand shoe is just a rotated
version of the horizontal one. So, the equations derived in the textbook (eqn.16-2 and
eqn.16-3) can directly be used. The first figure can be checked while finding the
necessary variables of the equations. The variables used in the formula are:
15
𝑎 = 120 + 15 = 120.94 𝑚𝑚, 𝛽 = arctan = 7.125 𝑑𝑒𝑔
120
𝜃 = 20 − 𝛽 = 12.875 𝑑𝑒𝑔, 𝜃 = 20 + 130 + 𝛽 = 142.875 𝑑𝑒𝑔
𝑝 = 1.8 𝑀𝑃𝑎, 𝑟 = 100𝑚𝑚, 𝑏 = 40𝑚𝑚, 𝑓 = 0.3
Also, note that since 𝜃 > 90 , the maximum pressure occurs at 𝜃 = 90 . From
equation 16-2;
𝑓𝑝 𝑏𝑟
𝑀 = sin(𝜃) ⋅ 𝑟 − 𝑎 ⋅ 𝑐𝑜𝑠(𝜃) 𝑑𝜃 = 314.6974 𝑁𝑚
sin(𝜃 )
From eqn.16-3:
𝑝 𝑏𝑟𝑎
𝑀 = sin (𝜃) 𝑑𝜃 = 1291.8834 𝑁𝑚
sin(𝜃 )
Moment equilibrium around the hinge gives the lever force:
𝑀 = 𝑀 − 𝑀 − 𝐹 ⋅ (120𝑚𝑚 + 115𝑚𝑚 + 50𝑚𝑚) = 0 → 𝐹 = 3333.9861 𝑁
Torque capacity of the left-hand shoe from eqn.16-6 is:
𝑓𝑝 𝑏𝑟 (cos(𝜃 ) − cos(𝜃 ))
𝑇 = = 382.7907 𝑁𝑚
sin(𝜃 )
For the right-hand shoe:
Since the lever force is found, the torque capacity of the right-hand shoe can be found.
At first, the maximum pressure on the right-hand shoe should be found. Frictional
moment and moment of normal forces of the right-hand shoe are proportional to the
values of the left-hand shoe (since dimensions are the same).
(314.6974 𝑁𝑚) ⋅ 𝑝 (1291.8834 𝑁𝑚) ⋅ 𝑝
𝑀 = & 𝑀 =
1.8 𝑀𝑝𝑎 1.8 𝑀𝑝𝑎
 c) Then, the torque capacity of one friction surface is;
4) A multiple-disc clutch has an outside diameter of 152 𝑚𝑚 and an inside diameter 320𝑁𝑚
𝑇 = = 26.67 𝑁𝑚
of 76 𝑚𝑚. The clutch material permits a maximum pressure of 276 𝑘𝑃𝑎 and has a 𝑛
The necessary actuating force can be found by rearranging Eq. 16-28.c as
coefficient of friction of 0.2. Uniform wear may be assumed, and a brake torque of
𝑑
320 𝑁𝑚 is to be applied. Determine: 3𝑇 1 − 𝐷
a) The actuating force 𝐹 = = 2255.6391 𝑁
𝑓𝐷 𝑑
b) The number of discs needed 1−
𝐷
c) Actual maximum pressure Then the actual maximum pressure is
2𝐹
d) Initially, the speed of the driving side is 400 𝑟𝑝𝑚, and the driven side is stationary. 𝑝 = = 248.61 𝑘𝑃𝑎
If the mass moments of inertia for the driving side and driven side are 𝐼 = 𝜋𝑑(𝐷 − 𝑑)
d) It is given in the case that:
30 𝑘𝑔𝑚 and 𝐼 = 21 𝑘𝑔𝑚 , respectively, what is the engagement time? What 𝑟𝑎𝑑
would be the speed just after clutching? 𝜃 = 𝜔 = 400 𝑟𝑝𝑚 = 41.89 ,𝜃 = 𝜔 = 0
𝑠
e) For the case in (d), determine the total energy absorbed by the clutch assembly Taking linear, angular acceleration during the engagement, from eqn.16-51, the
during the engagement. engagement time is:
𝐼 𝐼 (𝜔 − 𝜔 )
𝑡= = 1.617 𝑠
Solution 𝑇 (𝐼 + 𝐼 )
a) Assuming the clutch operates under the maximum permissible pressure of its Just after the engagement, the speeds of both sides are equal, 𝜔 = 𝜔 = 𝜔 :
material, then the actuating force is (from eqn.16-23): 𝑇 𝑇 𝑟𝑎𝑑
𝜔 = 𝜔 − 𝑡 = 𝜔 + 𝑡 = 24.64 = 235.29 𝑟𝑝𝑚
𝜋𝑝 𝑑 𝐼 𝐼 𝑠
𝐹= (𝐷 − 𝑑) = 2504.1258 𝑁 f) From eqn.16-52, the absorbed energyis:
2
b) The torque capacity of the clutch (from eqn.16-25): 𝐼 𝐼 (𝜔 − 𝜔 )
𝐹𝑓 𝐸= = 10.84 𝑘𝐽
𝑇= (𝐷 + 𝑑) = 28.547 𝑁𝑚 2(𝐼 + 𝐼 )
4
The total brake torque is 320 Nm, then the number of friction surfaces n is;
320𝑁𝑚
𝑛= = 11.2 → 𝑛 = 12
𝑇
The total number of discs becomes 𝑛 + 1 = 13.