Design of Clutches

Dr. SHARNAPPA JOLADARASHI

Associate Professor
Department of Mechanical Engineering
NITK Surathkal

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Design of Multi-Disc Clutches
Example 7: An oil immersed multi-disk clutch with cork sheet as the friction material is used on
a scooter engine. The friction disk of such a clutch is shown in Fig 7. The torque transmitted by
the clutch is 10N-m. The coefficient of friction between the cork sheet plate in the wet condition
is 0.2. The permissible pressure on the cork sheet is 0.1N/mm2. The inner and outer diameter of
the friction lining are 65 and 95mm respectively. There are radial slots, on the friction surface
for the circulation of the coolant, which reduces the effective friction area. To account for these
slots, the number of contacting surfaces can be increased by 5%. Assuming uniform wear theory,
calculate the required number of contacting surfaces.

Fig: 7

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Solution: M t  10 N  m, D  95mm, d  65mm,   0.2, pa  0.1N / mm 2

Step I: Operating force

 pa d  (0.1)(65)
P (D  d )  (95  65)  306.31N
2 2

Step II: Number of contacting surfaces

4M t 4(10 X 103 )
z   4.08
 P ( D  d ) (0.2)(306.31)(95  65)
Considering the effect of radial slots,
z  1.05(4.08) = 4.28or 5 surfaces

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Example 8: A multi-disk clutch consists of five steel plates and four bronze plates. The inner and
outer diameters of the friction disks are 75 and 150mm respectively. The coefficient of friction is
0.1 and the intensity of pressure on friction lining is limited to 0.3 N/mm2. Assuming uniform
wear theory, calculate:
(i) The required force to engage the clutch and (ii) power transmitting capacity at 750 rpm.
Solution: D  150mm, d  75mm,   0.1, n  750rpm, pa  0.3 N / mm 2
Number of steel plates = 5, Number of bronze plates = 4

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Example 8: A multi-disk clutch consists of five steel plates and four bronze plates. The inner and
outer diameters of the friction disks are 75 and 150mm respectively. The coefficient of friction is
0.1 and the intensity of pressure on friction lining is limited to 0.3 N/mm2. Assuming uniform
wear theory, calculate:
(i) The required force to engage the clutch and (ii) power transmitting capacity at 750 rpm.
Solution: D  150mm, d  75mm,   0.1, n  750rpm, pa  0.3 N / mm 2
Number of steel plates = 5, Number of bronze plates = 4
Step I: Required operating force
 pa d  (0.3)(75)
P (D  d )  (150  75)  2650.72 N
2 2
Step II: Power transmitting capacity
There are 5 steel plates and 4 bronze plates. Total plates are 9.
Number of disks = z+1 = 9 Therefore z = 8
 Pz (0.1)(2650.72)(8)
Mt  (D  d )  (150  75)  119282.4 N  mm
4 4
2 nM t 2 (750)(119282.4)
kW    9.37
60X106 60X106
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Example 9: An oil immersed multi disk clutch with moulded asbestos on one side and steel disks
on the other, is used in an application. The torque transmitted by the clutch is 75 N-m. The
coefficient of friction between the asbestos lining and the steel plate in the wet condition is 0.1.
The permissible intensity of pressure on the asbestos lining is 500kPa. The outer diameter of the
friction lining is kept as 100mm due to space limitation. Assuming uniform wear theory, calculate
the inside diameter of the disks, the required number of disks and the clamping force.

Solution: M t  75 N  m, D  100mm,   0.1, pa  500kPa

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Example 9: An oil immersed multi disk clutch with moulded asbestos on one side and steel disks
on the other, is used in an application. The torque transmitted by the clutch is 75 N-m. The
coefficient of friction between the asbestos lining and the steel plate in the wet condition is 0.1.
The permissible intensity of pressure on the asbestos lining is 500kPa. The outer diameter of the
friction lining is kept as 100mm due to space limitation. Assuming uniform wear theory, calculate
the inside diameter of the disks, the required number of disks and the clamping force.

Solution: M t  75 N  m, D  100mm,   0.1, pa  500kPa

Step I: Inside diameter of disks

 Pz
Mt  (D  d )
4
It is observed from the above expression that there are two unknowns d and z and one equation.
It cannot be solved unless we make some assumption. We will assume that the clutch is
transmitting maximum torque. The condition for this objective is written as,

d
 0.577
D
D  0.577(100)  57.7  58mm

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Step II: Clamping force
 pa d  (0.5)(58)
P (D  d )  (100  58)  1913.23 N
2 2
Step III: Required number of disks
4M t 4(75000)
z   9.92  10
 P ( D  d ) (0.1)(1913.23)(100  58)

Number of disks = z+1=10+1 = 11

6 plane steel disks and 5 steel disks will be used with attached asbestos lining.

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Design of Cone Clutches
Example 10: A cone clutch with asbestos friction lining transmits 30kW power at 500rpm. The
coefficient of friction is 0.2 and the permissible intensity of pressure is 0.35 N/mm2. The semi-
cone angle is 12.50 . The outer diameter is fixed as 300rpm from space limitations. Assuming
uniform wear theory, calculate:
(i) The inner diameter, (ii) the face width of the friction lining, (iii) the force required to engage
the clutch.
Solution: kW  30, n  500rpm,   0.2, pa  0.35 N / mm 2 ,   12.50 , D  300mm

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Example 10: A cone clutch with asbestos friction lining transmits 30kW power at 500rpm. The
coefficient of friction is 0.2 and the permissible intensity of pressure is 0.35 N/mm2. The semi-
cone angle is 12.50 . The outer diameter is fixed as 300rpm from space limitations. Assuming
uniform wear theory, calculate:
(i) The inner diameter, (ii) the face width of the friction lining, (iii) the force required to engage
the clutch.

Solution: kW  30, n  500rpm,   0.2, pa  0.35 N / mm 2 ,   12.50 , D  300mm

Step I: Inner diameter
60X106 ( kW ) 60 X 106 (30)
Mt    572957.8 N  mm
2 n 2 (500)
 pa d 2
Mt  (D  d 2 )
8sin 
(0.2) (0.35) d
572957.8  0
(300 2
 d 2
)
8sin(12.5 )
Rearranging terms,
d (3002  d 2 )  4511297.43
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The above equation is solved by trial and error method. The nearest value of d is 270.8mm.
Therefore, the inner diameter is taken as 270mm.
d  270mm
Step II: Face width of friction lining

Dd 300  270

b   69.3mm
2sin  2sin(12.50 )

Step III: Force required to engage clutch

4 M t sin  4(572957.8)sin(12.50 )
P   4351.25 N
 (D  d ) 0.2(300  270)

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Example 11: A cone clutch is used to connect an electric motor running at 1440 rpm with a
machine which is stationary. The machine is equivalent to a rotor of 150kg mass and radius of
gyration as 250mm. The machine has to be brought to the full speed of 1440 rpm from stationary
condition in 40s. The semi cone angle is 12.50 . The mean radius of the clutch is twice the face
width. The coefficient of friction is 0.2 and the normal intensity of pressure between contacting
surfaces should not exceed 0.1N/mm2. Assuming uniform wear criterion, calculate:
(i) The inner and outer diameter, (ii) the face width of friction lining, (iii) the force required to
engage the clutch, (iv) the amount of heat generated during each engagement of clutch.
Solution: n  1440rpm,   0.2, rm  2b, pa  0.1N / mm ,   12.5
2 0

For machines, m  150kg , k  250mm, t  40 s

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Example 11: A cone clutch is used to connect an electric motor running at 1440 rpm with a
machine which is stationary. The machine is equivalent to a rotor of 150kg mass and radius of
gyration as 250mm. The machine has to be brought to the full speed of 1440 rpm from stationary
condition in 40s. The semi cone angle is 12.50 . The mean radius of the clutch is twice the face
width. The coefficient of friction is 0.2 and the normal intensity of pressure between contacting
surfaces should not exceed 0.1N/mm2. Assuming uniform wear criterion, calculate:
(i) The inner and outer diameter, (ii) the face width of friction lining, (iii) the force required to
engage the clutch, (iv) the amount of heat generated during each engagement of clutch.
Solution: n  1440rpm,   0.2, rm  2b, pa  0.1N / mm ,   12.5
2 0

For machines, m  150kg , k  250mm, t  40 s

Step I: Inner and outer diameters

1  0

2 n 2 (1440)
2    150.80rad / s
60 60

2  1 150.80  0
   3.77rad / s 2
t 40
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 M t  I  mk 2  150(0.25) 2 (3.77)  35.34292 N  m
 pa d 2
Mt  (D  d 2 )
8sin 
(0.2) (0.1)d 2
 35342.92  0
(D  d 2 )
8sin(12.5 )

Rearranging the terms

d ( D 2  d 2 )  973978.34 (…a)

D  d  2b sin  (…b)
Since the mean radius of the clutch is twice the face width,
Dd (…c)
 2b
Dividing Eq. (c) by (b) 4

Dd 8b 4
 
D  d 2b sin  sin 

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Therefore,
D 4  sin  4  sin(12.50 )
   1.1144
d 4  sin  4  sin(12.5 )
0

D2
 1.2419
d2
Substituting this value in Eq. (a),

d (1.2419d 2  d 2 )  973978.34

d  159.09mm
D  1.1144d  1.1144(159.09)  177.29mm

Step II: Face width of friction lining

From Eq. (c),
D  d 177.29  159.09
b   42.05 N
8 8
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Step III: Force required to engage clutch

4M t sin  4(35342.92)sin(12.50 )
P   454.82 N
 (D  d ) 0.2(177.29  159.09)

Step IV: Heat generated during each engagement

2  1 0  150.8
avg    75.4rad / s
2 2
  avg (time)  75.4(40)  3016radians
Heat generated during engagement = work done by frictional torque

H g  M t  35.34(3016)  106585.44 N  m

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Design of Centrifugal Clutches
Example 12: A centrifugal clutch, transmitting 20kW at 750rpm consists of four shoes. The
clutch is to be engaged at 500rpm. The inner radius of the drum is 165mm. The radius of the
center of gravity of the shoes is 140mm when the clutch is engaged. The coefficient of friction is
0.3, while the permissible pressure on friction lining is 0.1N/mm2 Calculate:
(i) The mass of each shoe, (ii) the dimension of friction lining.
Solution: kW  20, n2  750rpm, n1  500rpm, z  4, rd  165mm, rg  140mm,   0.3, pa  0.1N / mm 2

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Example 12: A centrifugal clutch, transmitting 20kW at 750rpm consists of four shoes. The
clutch is to be engaged at 500rpm. The inner radius of the drum is 165mm. The radius of the
center of gravity of the shoes is 140mm when the clutch is engaged. The coefficient of friction is
0.3, while the permissible pressure on friction lining is 0.1N/mm2 Calculate:
(i) The mass of each shoe, (ii) the dimension of friction lining.
Solution: kW  20, n2  750rpm, n1  500rpm, z  4, rd  165mm, rg  140mm,   0.3, pa  0.1N / mm 2

Step I: Mass of each shoe

2 n2 2 (750)
2    78.54rad / s
60 60
2 n1 2 (500)
1    52.36rad / s
60 60

60X106 ( kW ) 60X106 (20)

Mt    254647.9 N  mm
2 n2 2 (750)

1000 M t 1000(254647.9)
m   2.68kg
 rg rd z (22  12 ) 0.3(140)(165)(4)(78.54 2  52.36 2 )

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Step II: Dimensions of friction lining
Fig. 12 illustrates four shoes with spider. It is assumed that the arc of contact of friction lining or
shoe subtends an angle of 700 at the center of the spider.
Let the dimensions of friction lining be designated as l and b as shown in Fig. 12.
l= contact length of friction lining with drum(mm), b=width of friction lining (mm)

 70 
 l  rd  165     201.59  200mm
 180 

Fig. 12

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The area of friction lining is (lb). The net force acting on the drum will be

( palb) …(a)
The net force acting on the drum is given by,

mrg (22  12 )

The net force acting on the drum = …(b)
1000

From (a) and (b),

mrg (22  12 )
( palb) 
1000

2.68(140)(78.542  52.362 )
(0.1)(200)b 
1000

b  64.29  65mm

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Example 13: A centrifugal clutch consists of four shoes, each having mass of 1.5kh.In the
engaged position, the radius to the center of gravity of each shoe is 110mm, while the inner
radius of the drum is 140mm. The coefficient of friction is 0.3. The pre-load in the spring is
adjusted in such a way that the spring force at the beginning of engagement is 700N. The running
speed is 1440rpm. Calculate:
(i) The speed at which the engagement begins, (ii) the power transmitted by the clutch at
1440rpm
Solution: n2  1440rpm, m  1.5kg , z  4, rd  140mm, rg  110mm,   0.3, Ps  700 N

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Example 13: A centrifugal clutch consists of four shoes, each having mass of 1.5kh.In the
engaged position, the radius to the center of gravity of each shoe is 110mm, while the inner
radius of the drum is 140mm. The coefficient of friction is 0.3. The pre-load in the spring is
adjusted in such a way that the spring force at the beginning of engagement is 700N. The running
speed is 1440rpm. Calculate:
(i) The speed at which the engagement begins, (ii) the power transmitted by the clutch at
1440rpm
Solution: n2  1440rpm, m  1.5kg , z  4, rd  140mm, rg  110mm,   0.3, Ps  700 N

Step I: The speed at which the engagement begins

The spring force is given by, m12 rg
Ps 
1000

1.512 (110)
700 
1000
1  65.13rad / s
601 60(65.13)
n1    621.98rpm
2 2
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Step II: The power transmitted by the clutch

2 n2 2 (1440)
2    150.80rad / s
60 60
 mrg rd z (22  12 ) 0.3(1.5)(110)(140)(4)(150.80 2  65.132 )
Mt    512784.60 N  mm
1000 1000

2 n2 M t 2 (1440)(512784.60)
kW  6
 6
 77.33
60X10 60X10

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Example 14: A single plate clutch is designed to transmit 10kW power at 2000rpm. The
equivalent mass and radius of gyration of the input shaft are 20kg and 75mm respectively.
equivalent mass and radius of gyration of the output shaft are 35kg and 125mm respectively.
Calculate:
(i) The time required to bring the output shaft to the rated speed from rest, (ii) the heat generated
during the clutching operation.
Solution: kW  10, n1  2000rpm
For input shaft m1  20kg , k1  75mm
For output shaft m2  35kg , k2  125mm

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Example 14: A single plate clutch is designed to transmit 10kW power at 2000rpm. The
equivalent mass and radius of gyration of the input shaft are 20kg and 75mm respectively.
equivalent mass and radius of gyration of the output shaft are 35kg and 125mm respectively.
Calculate:
(i) The time required to bring the output shaft to the rated speed from rest, (ii) the heat generated
during the clutching operation.

Solution: kW  10, n1  2000rpm

For input shaft m1  20kg , k1  75mm
For output shaft m2  35kg , k2  125mm
Step I: Time required to bring the output shaft to the rated speed
I1  m1k12  20(0.075) 2  0.1125kg  m 2
I1  m2 k22  35(0.125) 2  0.5469kg  m 2
2 n1 2 (2000)
1    209.44rad / s, 2  0
60 60
60X106 (kW ) 60X106 (10)
Mt    47746.48 N  mm
2 n1 2 (2000)
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 (1  2 ) I1I 2 (209.44  0)(0.1125)(0.5469)
t1    0.41s
( I1  I 2 ) M t (0.1125  0.5469)(47.746)

Step II: The heat generated during the clutching operation

1 (1  2 ) 2 I1I 2 1 (209.44  0) 2 (0.1125)(0.5469)

E   2046.45 J
2 ( I1  I 2 ) 2 (0.1125  0.5469)

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 Thank You

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