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Design of Machine Elements

Muhammad Ilyas, PhD

 Clutches, Brakes, Couplings

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 Internal Expanding Rim Clutches and Brakes
The internal-shoe rim clutch consists essentially of three elements:
1. mating frictional surface
2. means of transmitting the torque to and from the surfaces
3. actuating mechanism

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 Static Analysis of Clutches and Brakes
Many types of clutches and brakes can be analyzed by following a general
procedure:
1. Estimate, model, or measure the pressure distribution on the friction surfaces.
2. Find a relationship between the largest pressure and the pressure at any point.
3. Use the conditions of static equilibrium to find the braking force or torque and
the support reactions
A brake shoe is:
 self-energizing if its moment sense helps set the brake

 self-deenergizing if the moment resists setting the brake.

A self-acting or self-locking phenomenon is present and is independent of our

knowledge of the normal pressure distribution

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 Internal-Shoe (or Drum) Brake
Frictional material

Internal friction shoe geometry The geometry associated with an arbitrary

point on the shoe.
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 Internal-Shoe (or Drum) Brake
  Short shoe, acts at
  Defining the angle at which the
maximum pressure occurs when:
a) shoe exists in zone
b) shoe exists in zone
 Limitations on friction materials are
expressed in terms of the largest
allowable pressure on the lining
 Therefore, think in terms of and not
  Long shoe, acts at
about the amplitude of the sinusoidal
distribution that addresses locations off
the shoe.

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 Internal-Shoe: Force Analysis
 Normal force:

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 Internal-Shoe: Force Analysis
Moment of friction forces:
𝜃2
  𝑓 𝑝 𝑎 𝑏𝑟
𝑀 𝑓 =∫ 𝑓𝑑𝑁 ( 𝑟 − 𝑎   cos 𝜃 )=¿ ∫ sin 𝜃 ( 𝑟 − 𝑎  cos 𝜃 ) 𝑑 𝜃 ¿ (16–2)
sin 𝜃 𝑎 𝜃 1

Moment of Normal forces:

𝜃2
  𝑝𝑎 𝑎𝑏𝑟
𝑀 𝑁 =∫ 𝑑𝑁 ( 𝑎  sin 𝜃 )=¿ ∫ sin2 𝜃 𝑑 𝜃 ¿ (16–3)
sin𝜃 𝑎 𝜃 1

Actuating force must balance these moments (cw/ccw rotation)

  𝑀𝑁 − 𝑀𝑓   𝑀𝑁+ 𝑀𝑓
𝐹= (16–4) c.w. 𝐹= (16–7) c.c.w.
𝑐 𝑐

Torque applied to the drum by the brake shoe

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 Internal-Shoe: Force Analysis
To ease computation,
let’s define

Drum rotating clockwise

Drum rotating counter-clockwise

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 Internal-Shoe: Force Analysis

In using these equations it must be considered that:

1. The reference system always has its origin at the center of the drum.
2. The positive x-axis is taken through the hinge pin.
3. The positive y-axis is always in the direction of the shoe, even if this results in a
left-handed system.

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 Internal-Shoe: Force Analysis

In the preceding analysis, following assumptions are implied:

1. The pressure at any point on the shoe is assumed to be proportional to the
distance from the hinge pin, being zero at the heel.
2. The effect of centrifugal force has been neglected. In the case of brakes, the shoes
are not rotating, and no centrifugal force exists.
3. In clutch design, the effect of this force must be considered in writing the
equations of static equilibrium.
4. The shoe is assumed to be rigid.
5. The entire analysis has been based upon a coefficient of friction that does not vary
with pressure.

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 Example 16–2

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 Sample Problem (16–1)
Drum Frictional material

The figure shows an internal rim-type brake having an inside rim diameter of 300mm and a dimension
R=125mm. The shoes have a face width of 40 mm and are both actuated by a force of 2.2 kN (each). The
drum rotates clockwise. The mean coefficient of friction is 0.28.

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.

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 Sample Problem (16–1 continues…)

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 External Contracting Rim Clutches and Brakes
Equations 16-2 and 16-3 are repeated here
𝜃2
  𝑓 𝑝𝑎 𝑏𝑟
𝑀 𝑓 =∫ 𝑓 𝑑𝑁 𝑟 −𝑎   cos 𝜃 =¿
( ) ∫ sin 𝜃 ( 𝑟 − 𝑎   cos 𝜃 ) 𝑑 𝜃 ¿
sin 𝜃𝑎 𝜃 1

𝜃2
  𝑝𝑎 𝑎𝑏𝑟 2
𝑀 𝑁 =∫ 𝑑𝑁 𝑎  sin 𝜃 =¿
( ) ∫ sin 𝜃 𝑑 𝜃 ¿
sin𝜃 𝑎 𝜃 1

c.w.

c.c.w.

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 Sample Problem (16–5)

The block-type hand brake shown in the figure has a face width of 1.25 in and a mean
coefficient of friction of 0.25. For an estimated actuating force of 90 lbf, find the maximum
pressure on the shoe and find the braking torque.
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 External Contracting Rim Clutches and Brakes

A special case arises when the pivot is symmetrically located and also placed so that
the moment of the friction forces about the pivot is zero.
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 External Contracting Rim Clutches and Brakes

 To get a pressure-distribution relation, we note that lining wear is such as to retain
the cylindrical shape.
This means the abscissa component of wear is for all positions

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 Band-Type Clutches and Brakes

  Point of
maximum
pressure
 minimum
band tension
 maximum
band tension

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 Sample Problem (16–14)

  The figure depicts a band brake whose drum rotates counterclockwise at 200 rev/min. The drum diameter is
16 in and the band lining 3 in wide. The coefficient of friction is 0.20. The maximum lining interface
pressure is 70 psi.

a) Find the maximum brake torque, necessary force , and steady-state power.

b) Complete the free-body diagram of the drum. Find the bearing radial load that a pair of straddle-
mounted bearings would have to carry.

c) What is the lining pressure at both ends of the contact arc?

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 Frictional-Contact Axial Clutches

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 Frictional-Contact Axial Clutches

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 Disk (Caliper) Brakes

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 Sample Problem (16–17)
 A hydraulically operated multi-disk plate clutch has an effective disk outer diameter of 165mm
and an inner diameter of 100 mm. The coefficient of friction is 0.24, and the limiting pressure
is 830 kPa. There are six planes of sliding present.

a) Using the uniform wear model, estimate the axial force and the torque .

b) Let the inner diameter of the friction pairs be a variable. Complete the following table:

(mm) 50 75 100 125 150

(Nm)
c) What does the table show?

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 Cone Clutches and Brakes

  Preferred value of :

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 Cone Clutches and Brakes

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 Friction Materials

Lining materials should have the following characteristics.

a) High and reproducible coefficient of friction
b) Imperviousness to environmental conditions, such as moisture
c) The ability to withstand high temperatures, together with good thermal
conductivity and diffusivity, as well as high specific heat capacity
d) Good resiliency
e) High resistance to wear, scoring, and galling
f) Compatible with the environment
g) Flexibility

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 Area of Friction Material Required

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 Characteristics of Friction Materials for Brakes and Clutches

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 Friction Materials for Clutches

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 Miscellaneous Clutches and Couplings

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 Miscellaneous Clutches and Couplings

These clutches have the following characteristics:

a) They do not slip.

b) No heat is generated.

c) They cannot be engaged at high speeds.

d) Sometimes they cannot be engaged when both shafts are at rest.

e) Engagement at any speed is accompanied by shock.

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