Prepared by: Selim E.

Toktaş The cross-section of the key is,

Room: C-210 Phone: 5262
E-mail: ercihan.toktas@metu.edu.tr
𝑡 = 10 mm
ME 308 – MACHINE ELEMENTS II
TUTORIAL 7 𝑤 = 16 mm
COUPLINGS, BRAKES & CLUTCHES The proportions of the rigid sleeve made of cast iron are given as:
𝑑1 = 2𝑑 + 12.5 𝑚𝑚, 𝐿 = 3.5𝑑, D = 80 mm, take the length of each key as
5L/11.
Problem 1: Analyze the rigid sleeve coupling that transmits 40 kW at 350 rpm.
The coupling is shown in the sketch below. Solution:
2𝜋 rad
The operating speed of the shaft is, 𝜔 = 350 60 = 36.7 𝑠
40000
Transmitted torque is found as 𝑃 = 𝑇𝜔 → 𝑇 = = 1090 𝑁 ∙ 𝑚
36.7
Considering the overload factor, the maximum torque on the shaft is
𝑇 𝑚𝑎𝑥 = 𝑇(1.25) = 1360 𝑁 ∙ 𝑚
𝑑1 = 2𝑑 + 12.5 = 117 𝑚𝑚; this is only for geometrical design.
𝐿 = 3.5𝑑 = 182 𝑚𝑚
The maximum shear stress on rigid sleeve:
The rigid sleeve coupling is 𝐷 𝐷
𝑇𝑟 𝑇𝑚𝑎𝑥 𝑇𝑚𝑎𝑥 3
𝜏𝑠𝑙𝑒𝑒𝑣𝑒,𝑚𝑎𝑥 = = 𝜋 2 = 2 = (1360 ⋅ 10 )(40) = 16.5 𝑀𝑃𝑎
used for joining two shafts, 𝐽 4
(𝐷4 − 𝑑 4 ) 𝜋(𝐷 − 𝑑 )
4 𝜋(804 − 524 )
and the coupling is required 32 2 32
to transmit 25% overload. The allowable stress is 40 MPa. Hence the sleeve is safe.
The key and the shaft Shear stress induced in the key is calculated as:
material are the same, and the 𝐹 𝑇𝑚𝑎𝑥
𝜏𝑘𝑒𝑦 = = = 39.5 𝑀𝑃𝑎 < 50 𝑀𝑃𝑎
coupling is made of cast iron. 𝐴𝑠ℎ𝑒𝑎𝑟 𝑑 𝑤 5𝐿
Allowable shear stresses for 2 11
So it is safe.
the cast iron and the shaft material are 40 MPa and 50 MPa, respectively.
The bearing stress induced in the key:
The width of the key is 16 mm, the thickness is 10 mm, and the diameter of the 𝐹 𝑇𝑚𝑎𝑥
shaft is 52 mm. The bearing strength of the shaft material is 130 MPa, and the 𝜎𝑘𝑒𝑦,𝑏𝑒𝑎𝑟𝑖𝑛𝑔 = = = 126.5 𝑀𝑃𝑎
𝐴𝑏𝑒𝑎𝑟𝑖𝑛𝑔 𝑑 𝑡 5𝐿
cast iron is 140 MPa. 2 2 11

𝜎𝑘𝑒𝑦,𝑏 < 𝜎𝑘𝑒𝑦,𝑏,𝑎𝑙𝑙 So the key is safe under bearing stress as well.
Problem 2: For the design of the band brake shown in the figure below, Solution:
determine:
a) The brake torque
b) The maximum actuating force applied to the lever, which is pivoted about
point O.
T
c) Self-locking characteristics of the brake. (Neglect the weights of the C
components)
B' A'
300 mm N2
𝑇 N1
0.1N 2
0.1N1
P1
P2

350 𝑚𝑚 a) According to the direction of rotation, larger force, and maximum pressure
𝑝𝑎 occurs at point A’.
The friction coefficients between the band and the pipe and the pipe and the 𝑃2 > 𝑃1
From eq. 16-21:
block are 0.30 and 0.10, respectively. The band can withstand a maximum of
1 𝑀𝑃𝑎 of pressure. The width of the band (𝑏) and outer radius of the pipe (𝑟) 𝑃2 = 𝑝𝑎 𝑏𝑟 = 1𝑀𝑃𝑎(20𝑚𝑚)300𝑚𝑚
are 20 mm and 300 mm, respectively. 𝑃2 = 6000𝑁
The angle of wrap, 𝜙 = 180°
From eq. 16-19:
𝑃2
= 𝑒 𝑓𝜙
𝑃1
𝑃2 6000
𝑃1 = 𝑓𝛼 = 0.3(𝜋) = 2338𝑁
𝑒 𝑒
Considering impending motion at contact surfaces, write force and moment
balances:
∑𝐹𝑥 = 0
𝑁1 cos 60 − 0.1𝑁1 cos 30 − 𝑁2 cos 60 − 0.1𝑁2 cos 30 = 0
𝑁1 (0.5 − 0.05√3) − 𝑁2 (0.5 + 0.05√3) = 0 (1)

∑𝐹𝑦 = 0
𝑁1 cos 30 + 0.1𝑁1 cos 60 + 𝑁2 cos 30 − 0.1𝑁2 cos 60 − 6000 − 2338 = 0
𝑁1 (0.05 + 0.5√3) + 𝑁2 (−0.05 + 0.5√3) − 6000 − 2338 = 0 (2)

Solving equations (1) and (2) yields:

𝑁1 = 5592 N
𝑁2 = 3941 N

∑𝑀𝑐 = 0
𝑇 − (𝑃2 − 𝑃1 ) ⋅ 𝑟 − 0.1 ⋅ (𝑁1 + 𝑁2 ) ⋅ 𝑟 = 0

Total brake capacity is:

𝑇 = 1385 N ⋅ m

b) Free body diagram of the actuating lever is:

O P2
70.711mm 350 mm

P3 A

P
Moment equilibrium about the pivot point, O, of the lever gives force
required:
∑𝑀𝑂 = 0
𝑃 ⋅ (350 + 50√2) = 𝑃2 (50√2)
𝑃 = 0.1681𝑃2
𝑃 = 1008 N

c) This band-type brake is not self-energizing. The condition of self-locking is

such that the force required to actuate braking is smaller than or equal to zero
(𝐹 ≤ 0). In that condition, there would be no need for any braking force. Thus,
the brake would be self-locking. However, there is always a need for actuating
force to start braking action, which is at most 1008 N.
Problem 3: For the double long shoe external drum brake shown in the figure,
determine the maximum force 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 design parameters of the brake mechanism are:
Face width of the shoes, b = 40 mm
Coefficient of friction between the drum and the shoes, f = 0.3
G one needs to find the brake forces on the shoes in terms of lever force, F.
Figure 1
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.
Note the “l” stands for left-hand shoe, and “r” stands for right-hand shoe. Now,
From the moment equilibrium on the pin at G (pin of L bar):
∑ 𝑀 = 𝐹(150) − 𝐹𝑙 (50) = 0 → 𝐹𝑙 = 3𝐹
From force equilibriums:
∑ 𝐹𝑥 = 𝐹𝑙 − 𝐹𝑟1 = 0 → 𝐹𝑟1 = 𝐹𝑙 = 3𝐹
∑ 𝐹𝑦 = 𝐹 − 𝐹𝑟2 = 0 → 𝐹𝑟2 = 𝐹
After finding the forces acting on the shoes, it is now possible to pass on the
analysis of the brake mechanism. The figure below is used to represent the
shoes separately to understand the system better.
In Figure 2, it can be seen that the 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.
Firstly, the left-hand shoe is considered the maximum pressure applied on it. (eqn.16-2 and eqn.16-3) can directly be used. The first figure can be checked
The explanation of this fact comes from the self-energizing property of the left- while finding the necessary variables of the equations.
hand shoe. For the left-hand shoe, the frictional moment, 𝑀𝑓 , has a decreasing The variables used in the formula are:
effect on the moment of normal forces, 𝑀𝑁 . This maximizes the normal force 𝑎 = √1202 + 152 = 121 mm
on the shoe, thus maximizing the pressure. However, if the right-hand shoe is 15
𝛽=tan−1 ( ) = 7. 1𝑜
considered, the maximum possible 𝑀𝑁 is limited by 𝑀𝑓 . So, the lever force is 120
considered with respect to the left-hand shoe’s torque capacity, and then the 𝜃1 = 20 − 𝛽 = 20 − 7.1 = 12. 9𝑜 = 0.225 𝑟𝑎𝑑
𝜃2 = 20 + 130 − 𝛽 = 142. 9𝑜 = 2.494 𝑟𝑎𝑑
torque capacity of the right-hand shoe is considered.
𝑝𝑎 = 1.8 MPa
The shoes in this brake mechanism have the same geometrical parameters. The 𝑟 = 100 mm
only difference between them is the direction of 𝑀𝑓 . So, 𝑀𝑓 and 𝑀𝑁 are found Also, note that since 𝜃2 > 90, maximum pressure occurs at 𝜃𝑎 = 90°.
for the left-hand shoe, and same values are applied to the right-hand shoe. From eqn.16-2:
𝑓𝑝𝑎 𝑏𝑟 𝜃2
𝑀𝑓 = ∫ 𝑠𝑖𝑛( 𝜃)(𝑟 − 𝑎 𝑐𝑜𝑠( 𝜃))𝑑𝜃
𝑠𝑖𝑛( 𝜃𝑎 ) 𝜃1
𝜃=𝜃2
𝑓𝑝𝑎 𝑏𝑟 1
𝑀𝑓 = [(−𝑟 𝑐𝑜𝑠( 𝜃)) − 𝑎 (− 𝑐𝑜𝑠( 2𝜃))]
𝑠𝑖𝑛( 𝜃𝑎 ) 4 𝜃=𝜃1
0.3(1.8⋅106 )0.040(0.100) 1 𝜃=2.494
𝑀𝑓 = [−0.100 𝑐𝑜𝑠( 𝜃) + 0.121 4 𝑐𝑜𝑠( 2𝜃)]
𝑠𝑖𝑛(𝜋/2 ) 𝜃=0.225
𝑀𝑓 = 341.8 N.m
From eqn.16-3:
𝑝𝑎 𝑏𝑟𝑎 𝜃2 2
𝑀𝑁 = ∫ 𝑠𝑖𝑛 ( 𝜃)𝑑𝜃
𝑠𝑖𝑛( 𝜃𝑎 ) 𝜃1
𝑝𝑎 𝑏𝑟𝑎 𝜃2 1 − 𝑐𝑜𝑠( 2𝜃)
𝑀𝑁 = ∫ ( ) 𝑑𝜃
𝑠𝑖𝑛( 𝜃𝑎 ) 𝜃1 2
𝜃=𝜃2
𝑝𝑎 𝑏𝑟𝑎 𝜃 1
𝑀𝑁 = [ − 𝑠𝑖𝑛( 2𝜃)]
𝑠𝑖𝑛( 𝜃𝑎 ) 2 4 𝜃=𝜃1
6 𝜃=2.494
1.8 ⋅ 10 (0.040)0.100(0.121) 𝜃 1
𝑀𝑁 = [ − 𝑠𝑖𝑛( 2𝜃)]
𝑠𝑖𝑛( 𝜋/2) 2 4 𝜃=0.225
𝑀𝑁 = 1292.7 N.m
Moment equilibrium around the hinge gives the lever force:
Figure 2
∑ 𝑀 = 𝑀𝑁 − 𝑀𝑓 − 𝐹𝑙 (0.120 + 0.115 + 0.050) = 0
For left-hand shoe:
1292.7 − 341.8 − 3(𝐹)0.285 = 0
When looked at the detailed figure, it is seen that the left-hand shoe is just a
𝐹 = 1112.2 N
rotated version of the horizontal one. So, the equations derived in the textbook
Torque capacity of the left-hand shoe from eqn.16-6 is:
𝑓𝑝𝑎 𝑏𝑟 2 (𝑐𝑜𝑠( 𝜃1 ) − 𝑐𝑜𝑠( 𝜃2 ))
𝑇𝐿 =
𝑠𝑖𝑛( 𝜃𝑎 )
0.3(1.8 ⋅ 106 )0.040(0.1002 )(𝑐𝑜𝑠( 12.9) − 𝑐𝑜𝑠( 142.9))
𝑇𝐿 =
𝑠𝑖𝑛( 90)
𝑇𝐿 = 382.8 N∙m

For 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 left-hand shoe values (since dimensions are the same).
341.8𝑝𝑎 1292.7𝑝𝑎
𝑀𝑓 = & 𝑀𝑁 =
1.8 1.8
Moment equilibrium around the hinge:
0.080
∑ 𝑀 = 𝑀𝑁 + 𝑀𝑓 − 𝐹𝑟1 (0.115 + 0.120) + 𝐹𝑟2 ( − 0.020) = 0
2
1292.7𝑝𝑎 341.8𝑝𝑎
+ − 3(𝐹)0.235 + 𝐹(0.015) = 0
1.8 1.8
908𝑝𝑎 = 0.69𝐹
For 𝐹 = 1112.2 N → 𝑝𝑎 = 0.845 MPa
Torque capacity of the right-hand shoe is:
𝑓𝑝𝑎 𝑏𝑟 2 (𝑐𝑜𝑠( 𝜃1 ) − 𝑐𝑜𝑠( 𝜃2 ))
𝑇𝑅 =
𝑠𝑖𝑛( 𝜃𝑎 )
0.3(0.845 ⋅ 106 )0.040(0.1002 )(𝑐𝑜𝑠( 12.9) − 𝑐𝑜𝑠( 142.9))
𝑇𝑅 =
𝑠𝑖𝑛( 90)
𝑇𝑅 = 179.7 N.m
So, the braking capacity of the mechanism is:
𝑇 = 𝑇𝐿 + 𝑇𝑅 = 382.8 + 179.7 = 562.5 N.m
Problem 4: A multiple-disc clutch has an outside diameter of 152 mm and an Solution
inside diameter of 76 mm. The clutch material permits a maximum pressure of a) Assuming the clutch operates under the maximum permissible pressure of its
276 kPa and has a coefficient of friction of 0.2. Uniform wear may be assumed, material, then the actuating force is (from eqn.16-23):
𝜋𝑝𝑎 𝑑
and a brake torque of 320 Nm will be applied. Determine 𝐹= (𝐷 − 𝑑)
a) The actuating force 2
3 )(0.076)
𝜋(276.10
b) The number of discs needed 𝐹= (0.152 − 0.076) = 2504 𝑁
2
c) Actual maximum pressure
d) Initially, the speed of the driving side is 400 rpm, and the driven side is b) The torque capacity of the clutch (from eqn.16-25):
stationary. If the mass moments of inertia for the driving side and driven
side are I1=30 kg.m2 and I2=21 kg.m2, respectively, what is the engagement 𝐹𝑓 (2504)0.2
𝑇= (𝐷 + 𝑑) = (0.152 + 0.076) = 28.5𝑁𝑚
time? What would be the speed just after clutching? 4 4
e) For the case in (d), determine the total energy absorbed by the clutch The total torque is 320 Nm, then the number of friction surfaces n is.
assembly during the engagement.
320
𝑛 = 28.5 = 11.2

Round up and take n as 12

Total number of discs = 𝑛 + 1 = 13

c) Then, the torque capacity of one friction surface is

320
𝑇= = 26.7 𝑁𝑚
12

The necessary actuating force can be found by rearranging eq. 16-25

 4𝑇 4(26.7)
𝐹= = = 2342 𝑁
𝑓(𝐷 + 𝑑) 0.2(0.152 + 0.076)

Then the actual maximum pressure is

2𝐹 2(2342)
𝑃𝑎 = = = 258 𝑘𝑃𝑎
𝜋𝑑(𝐷 − 𝑑) 𝜋(0.076)(0.152 − 0.076)

d) It is given in the case that:

2𝜋
𝜃̇1 = 𝜔1 = 400 rpm = 400 =41.9 rad/s & 𝜃̇2 = 𝜔2 = 0
60
Taking linear, angular acceleration during the engagement, from eqn.16-51,
the engagement time is:

𝐼1 𝐼2 (𝜔1 − 𝜔2 ) (30)21(41.9 − 0)
𝑡1 = = = 1.62 s.
𝑇(𝐼1 + 𝐼2 ) 320(30 + 21)

Just after the engagement, the speeds of both sides are equal, 𝜃̇1 = 𝜃̇2 = 𝜃𝑓̇ :
𝑇 𝑇
𝜃𝑓̇ = 𝜔1 − 𝑡1 OR 𝜃𝑓̇ = 𝜔2 + 𝑡1
𝐼1 𝐼2
𝜃𝑓̇ = 24.7 rad/s = 236 rpm

e) From eqn.16-52, energy absorbed is:

𝐼1 𝐼2 (𝜔1 − 𝜔2 )2 (30)21(41.9 − 0)2
𝐸= =
2(𝐼1 + 𝐼2 ) 2(30 + 21)
𝐸 = 10.8 kJ
Problem 5: Figure 3 below shows an internal rim-type brake having an inside
rim diameter of 400 mm and a dimension R = 175 mm. The shoes have a face
width of 60 mm and are both actuated by a force of 3.8 kN. The drum rotates
clockwise. The mean coefficient of friction is 0.3. Assume clockwise rotation.
a) Find the maximum pressure and indicate the shoe on which it occurs.
b) Estimate the braking torque effected by each shoe, and find the total braking
torque.
c) Estimate the resulting hinge-pin reactions.
Problem 6: The block-type hand brake shown in Figure 4 has a face width of
30 mm, a radius of 150 mm and a mean coefficient of friction of 0.2. For an
estimated actuating force of 400 N, find the maximum pressure on the shoe and
find the braking torque. Dimensions of the problem are 𝑙1 =150 mm, 𝑙2 =200 mm
and 𝑙3 =300 mm.
𝑙2 𝑙3

𝑙1

Figure 4

Figure 3