Design of Clutches

Dr. SHARNAPPA JOLADARASHI

Associate Professor
Department of Mechanical Engineering
NITK Surathkal

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Design of Plate Clutches
Example : A single-plate clutch has a friction disc with inner and outer radii of 20 mm
and 40 mm, respectively. The friction lining in the disc is made in such a way that the
coefficient of friction μ varies radially as μ = 0.01r, where r is in mm. The clutch needs to
transmit a friction torque of 18.85 kN-mm. As per uniform pressure theory, the pressure on
the disc in MPa is?

DATA: ri = r2 = 20 mm; ro=r1= 40 mm; μ = 0.01r; Mt= 18.85kN-mm

Example : A single-plate clutch has a friction disc with inner and outer radii of 20 mm
and 40 mm, respectively. The friction lining in the disc is made in such a way that the
coefficient of friction μ varies radially as μ = 0.01r, where r is in mm. The clutch needs to
transmit a friction torque of 18.85 kN-mm. As per uniform pressure theory, the pressure on
the disc in MPa is?

DATA: ri = r2 = 20 mm; ro=r1= 40 mm; μ = 0.01r; Mt= 18.85kN-mm

Example 1: A plate clutch consists of one pair of contacting surfaces. The inner and outer
diameters of the friction disk are 100 and 200mm respectively. The coefficient of friction is 0.2
and the permissible intensity of pressure is 1N/mm2. Assuming uniform-wear theory, calculate
the power transmitting capacity of the clutch at 750rpm.
Solution: D  200mm, d  100mm,   0.2, pa  1N / mm 2 , n  750rpm

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Example 1: A plate clutch consists of one pair of contacting surfaces. The inner and outer
diameters of the friction disk are 100 and 200mm respectively. The coefficient of friction is 0.2
and the permissible intensity of pressure is 1N/mm2. Assuming uniform-wear theory, calculate
the power transmitting capacity of the clutch at 750rpm.
Solution: D  200mm, d  100mm,   0.2, pa  1N / mm 2 , n  750rpm

Step I Operating force

 pa d  (1)(100)
P (D  d )  (200  100)  15707.96 N
2 2
Step II Power transmitting capacity

P (0.2)(15707.96)
Mt  (D  d )  (200  100)  235619.4 N  mm
4 2

2 nM t 2 (750)(235619.4)
kW    18.51
2 4

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Example 2: Assume the data given in Example 1 and calculate the power transmitting capacity
of the clutch using uniform pressure theory
Solution: D  200mm, d  100mm,   0.2, pa  1N / mm 2 , n  750rpm

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Example 2: Assume the data given in Example 1 and calculate the power transmitting capacity
of the clutch using uniform pressure theory
Solution: D  200mm, d  100mm,   0.2, pa  1N / mm 2 , n  750rpm
Step I Operating force
p  (1)
P (D2  d 2 )  (200 2  100 2 )  23561.95 N
4 4

Step II Power transmitting capacity

 P ( D3  d 3 )
(0.2)(23561.95) P (2003  1003 )
Mt    366519.22 N  mm
3 (D  d )
2 2
3 (200  100 )
2 2

2 nM t 2 (750)(366519.22)
kW    28.79
(60)(10) (60)(106 )

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Example 3: An automotive plate clutch consists of two pairs of contacting surfaces with an
asbestos friction lining. The torque transmitting capacity of the clutch is 550N-m. The coefficient
of friction is 0.25 and the permissible intensity of pressure is 0.5 N/mm2. Due to space
limitations, the outer diameter of the friction disk is fixed as 250mm. Using uniform wear theory,
calculate (i) the inner diameter of the friction disk; and (ii) the spring force required to keep the
clutch in an engaged position.
Solution: M t  550 N  m, D  250mm,   0.25, pa  0.5 N / mm 2

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Example 3: An automotive plate clutch consists of two pairs of contacting surfaces with an
asbestos friction lining. The torque transmitting capacity of the clutch is 550N-m. The coefficient
of friction is 0.25 and the permissible intensity of pressure is 0.5 N/mm2. Due to space
limitations, the outer diameter of the friction disk is fixed as 250mm. Using uniform wear theory,
calculate (i) the inner diameter of the friction disk; and (ii) the spring force required to keep the
clutch in an engaged position.
Solution: M t  550 N  m, D  250mm,   0.25, pa  0.5 N / mm 2
Step I: Inner diameter of friction disk
The friction disk of the automotive clutch is fixed between the flywheel on one side and the
pressure plate on the other. The friction lining is provided on both sides of the friction disk. There
are two pairs of contacting surfaced- one between the flywheel and the friction disk and the other
between the friction disk and the pressure plate. Therefore the torque transmitted by one pair of
contacting surfaces is (550/2) or 275N-m.
 Pa d
Mt  (D2  d 2 )
8
 (0.25)(0.5) d
(275 X 103 )  (250 2  d 2 )
8

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Rearranging the terms, we have
d (2502  d 2 )  5602254
The above equation is solved by trial and error method. It is a cubic equation , with the following
three roots: (i) d=174.16mm, (ii) d=112.9mm, (iii) d=-286.46mm
Mathematically, all the three answers are correct. The inner diameter cannot be negative. As a
design engineer, one should select the inner diameter as 174.16mm, which results in a minimum
area of friction lining compared with 112.29mm. For minimum cost of friction lining,
d=174mm
Step II: Required spring force

 pa d  (0.5)(174)
P (D  d )  (250  174)  10386.11N
2 2

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Example 4: A single plate clutch consists of one pair of contacting surfaces. Because of space
limitations, the outer diameter of the friction disk is fixed as D. The permissible intensity of
pressure is pa and the coefficient of friction, μ. Assuming uniform wear Theory, plot the variation
of the torque transmitting capacity against the ratio of diameters (d/D). Show that the torque
transmitting capacity of the clutch is maximum, when (d/D) is equal to 0.577.
Solution:

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Example 4: A single plate clutch consists of one pair of contacting surfaces. Because of space
limitations, the outer diameter of the friction disk is fixed as D. The permissible intensity of
pressure is pa and the coefficient of friction, μ. Assuming uniform wear Theory, plot the variation
of the torque transmitting capacity against the ratio of diameters (d/D). Show that the torque
transmitting capacity of the clutch is maximum, when (d/D) is equal to 0.577.
Solution:
Step I: Variation of torque capacity against the ratio (d/D)
d …..(a)
x
D

 Pa D
Mt  (D2  d 2 ) …..(b)
8
Substituting Eq. (a) in Eq. (b), we have
 Pa D 3 …..(c)
Mt  [ x(1  x 2 )]
For maximum torque capacity, 8

 
(M t )  0 or [ x(1  x 2 )]  0
x x
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 1
1  3 x 2  0 x   0.577 …..(d)
3
Equation © is rearranged in the following form:

Mt8
 x(1  x 2 )
 Pa D 3

The left hand side is called the torque characteristic. The variation of the torque characteristic
against x is shown in Fig. 4
Step II: Optimum ratio
From (d), the condition for maximum torque
capacity is given by,
D
 3  1.732
d
d 1
  0.577
D 3

Fig. 4: Variation of torque against d/D

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Example 5: A single plate clutch consists of only pair of contacting surfaces. It is used for an
engine, which develops a maximum torque of 120N-m. Assume a factor of safety of 1.5 to
account for slippage at full-engine torque. The permissible intensity of pressure is 350kPa and
the coefficient of friction is 0.35. Assuming uniform wear theory, calculate the inner and outer
diameters of the friction lining.
Solution: M t  120 N  m,( fs )  1.5,   0.35, pa  350kPa

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Example 5: A single plate clutch consists of only pair of contacting surfaces. It is used for an
engine, which develops a maximum torque of 120N-m. Assume a factor of safety of 1.5 to
account for slippage at full-engine torque. The permissible intensity of pressure is 350kPa and
the coefficient of friction is 0.35. Assuming uniform wear theory, calculate the inner and outer
diameters of the friction lining.
Solution: M t  120 N  m,( fs )  1.5,   0.35, pa  350kPa
Step I: Inner diameter of friction lining
M t  1.5(120)  180 N  m

 Pa D
Mt  (D2  d 2 )
8
 (0.35)(0.35) d
180000  (D2  d 2 )
8

d (3d 2  d 2 )  3741765.19

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The above expression indicates two unknowns, D and d, and one equation. It cannot be solved,
unless we make some assumption. We will assume that the clutch is transmitting maximum
torque. As explained in the previous example, the condition for this objective is written as,

d
 0.577
D
d2
D  2
2
3d 2
0.577
Substituting Eq. (b) in Eq. (a),
d (3d 2  d 2 )  3741765.19

2d 3  3741765.19

 d  123.22mm
Step II: Outer diameter of friction lining
d 123.22
D   213.55mm
0.577 0.577

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Example 6: An automobile plate clutch consists of two pairs of contacting surfaces with
asbestos friction lining. The maximum engine torque is 250N-m. The coefficient of friction is
0.35. The inner and outer diameters of friction lining are 175 and 250mm respectively. The
clamping force is provided by nine springs, each compressed by 5mm to give a force of 800N,
when the clutch is new:
(i) What is the factor of safety with respect to slippage when the clutch is brand new?
(ii) What is the factor of safety with respect to slippage after initial wear has occurred?
(iii) How much wear of friction lining can take place before the clutch will slip?

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Example 6: An automobile plate clutch consists of two pairs of contacting surfaces with
asbestos friction lining. The maximum engine torque is 250N-m. The coefficient of friction is
0.35. The inner and outer diameters of friction lining are 175 and 250mm respectively. The
clamping force is provided by nine springs, each compressed by 5mm to give a force of 800N,
when the clutch is new:
(i) What is the factor of safety with respect to slippage when the clutch is brand new?
(ii) What is the factor of safety with respect to slippage after initial wear has occurred?
(iii) How much wear of friction lining can take place before the clutch will slip?
Step I: Factor of safety against slippage for new clutch
There are two parts of contacting surfaces. The torque transmitted by one pair should be (250/2)
or 125N-m.
M t  250 N  m, D  250mm, d  175mm,   0.35, P  800 N ,   5mm

M t  125X103  125000 N  mm, P  9(800)  7200 N

When the clutch is brand new, the uniform pressure theory is applicable.
 P ( D3  d 3 )
(0.35)(7200) (2503  1753 )
Mt    270529.41N  mm
3 (D  d )
2 2
3 (250  175 )
2 2

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 270529.41
( fs )   2.16
125000
When initial wear has occurred, the uniform wear theory is applicable. We will assume that there
is negligible change in spring force after initial wear has occurred.

P (0.35)(7200)
Mt  (D  d )  (250  175)  267750 N  mm
3 3
267750
( fs )   2.14
125000
Step II: Wear of friction lining before slippage
The clutch will slip when the spring force is no longer in a position to transmit the engine
torque.
The spring force required to transmit the engine torque of 125000N-m is given by,
P
Mt  (D  d )
4
0.35 P
125000  (250  175)
4
P  3361.34 N
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Since there are nine springs, the force per spring is (3361.34/9=373.48N). When the force per
spring will be less than 373.48N, the clutch will slip. Suppose x is the wear of friction lining for
this condition.

Compression of spring = initial compression-x = (5-x)mm

Stiffness of spring =  373.48  N / mm (…a)
 5 x 
Initially, each spring is compressed by 5mm to give a force of 800N.

 800  (…b)
Stiffness of spring =   N / mm
 5 
From (a) and (b),
 373.48   800 
  
 5  x   5 
 x  2.67 mm
When the wear of friction lining is more than 2.67mm, the spring force will be less than
373.48N and the clutch will slip
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 Thank You

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