Calculation example of cone clutch:
Given : It is required to accelerate a machine from n2 = 0 to n2 = n1 = 750
rev/min in tR = 1 s with a continuously running motor by means of a clutch.
GD2 of the rotating masses is 30 kgfm2 referred to the clutch shaft, the
steady state torque is MH = 1410 kgfcm, the number of operations per hour
is z = 60. The air temperature L = 250C.
Selected: From Table 29/2 asbestos lining with plastic, μ ≈ 0.35 (dry), qv =
0.15 cm3/HPh, utilization factor for lining surface y = 0.9, clearance l = 0.1
cm, wearable thickness lining sv = 0.3 cm, hand force H = 10 kgf, efficiency of
linkage ηG ≈ 0.9, half the cone angle δ = 250, sin δ = 0.422.
Required: MR, b, d, NR, , , p, LB, Ps, s, i, h.
Friction torque MR: From equation 29/5, Am = GD2 n2/7200 = 2350 kgfcm.
From equation 29/6, MB = 1910 Am/(n tR) = 5970 kgfcm. From equation 29/2,
MR = MB + MH = 7380 kgfcm.
Friction power NR : From equation 29/9 , AR = MRn1tR/1910 = 2900 kgfm.
From equation 29/10, NR = AR z/270 000 = 0.64 HP.
Main dimensions d and b: From Table 29/4, KT =1.2, b/d = 0.2 and j =1, then
from equation 29/23, d = 28.3 cm. Selected, d = 30 cm, b = d(b/d)= 6 cm.
Heating: The effective cooling area Fk consists only of the external surface of
the outer cone since the inner cone is insulated by the friction lining and the
internal surfaces are not in contact with the outside air.
Fk ≈ πdbs + πd2/4 = 0.146 m2 with bs = 8 cm, vk = dn/1910 = 11.8 m/s. αk ≈ 4.5
+ 6 vk3/4 = 42.9 from equation 29/28.
From equation 29/27 hu = 632 NR/FK αK = 64.6 0C.
= L + hu = 25 + 64.6 = 90 0C.
Mean pressure p: from Table 29/1, F = π d b y = 510 cm2, U = 2 MR/d = 492
kgf, p = U/(Fμ) = 2.76 kgf/cm2.
Lining life LB : From Table 29/1, Vv = F sv = 153 cm3. From equation 29/31,
Operating data: From Table 29/1, the operating force Ps = U sin δ/μ = 590
kgf and the movement s = l/sin δ = 0.237 cm.
From equation 29/26 the reduction ratio of the lingkage is l = Ps/(HηG) =
65.7 with H = 10 kgf.
From equation 29/25 the hand movement is h = si = 15.6 cm.
Calculation example of disk clutch:
Given: Service data, MR = 7380 and NR = 0.64
Selected: Friction pairing between steel and sintered metals with spiral
grooves and oil lubricated, μ = 0.1, qv = 0.025 cm3/HPh from Table 29/2,
j=10, clearance l = 0.025 cm, wearable lining thickness sv = 0.035 cm, hand
force H = 10 kgf, efficiency of linkage ηG ≈ 0.8, utilisation factor for lining
surface y = 0.7.
Required: d, b, LB, p, Ps, s, i, h.
Main dimensions d and b: From Table 29/4, KT = 0.7 and b/d = 0.15. Then
from equation 29/23: d ≈ 17 cm and b = 2.6 cm for NR = 0.64.
Lining life LB : From Table 29/1, F = π d b y j = 777 cm2; Vv = F sv = 27 cm3.
From equation 29/31,
Mean pressure p: From Table 29/1
Operating data: From Table 29/1, the operating force
Operating movement s = l j = 0.25 cm. From equation 29/26 the reduction
ratio of the linkage i;
From equation 29/25 the hand movement is h = s i = 27 cm.
Brakes
The main function of the brake is to stop the shaft, set the
rotation of the shaft, and also prevent unwanted rotation.
Mechanical braking effect is obtained by friction, and electrically
with a magnetic powder, reversed phase, exchange pole.
Type of brakes
1. Disk Brakes
2. Band Brake
3. Block Brake
a) Block Brake with Short Shoe
b) Pivoted Block Brake with long shoe
c) Brake with pivoted symmetrical shoe
4. Drum brake
Disk brakes
sometimes spelled as "disk" brakes, use a flat, disk-
shaped metal rotor that spins with the wheel. When the
brakes are applied, a caliper squeezes the brake pads
against the disc, slowing the wheel.
Brake systems
Principal works of disk brake
When a brake lever or pedal
is pressed, the push rod
which is connected to lever
or pedal and master cylinder
piston pushes the master
cylinder piston. This
movement allows the master
cylinder piston to slide and
push the return spring inside
the bore of master cylinder,
which generates pressure in
reservoir tank. At this
moment a primary seal
allows the brake fluid of
reservoir tank to flow over it
into the brake hosepipes.
A secondary seal ensures that the brake fluid
does not go other side.
Disk brake
Torque :
Where :
Advantages of disk brake
1. Disk brake requires less effort (brake torque) to stop the
vehicle compare to drum brake.
2. It generates less heat compare to drum brake for the same
brake torque.
3. Ease of maintenance as disk brake is outside the wheel rim.
4. It cools down faster compare to drum brake.
5. If worn out brake shoes are not changed at proper time it can
cut the brake drum in drum brake. Disk brake does not have
such problem.
6. It is less likely to skid compare to drum brake in wet
condition.
7. It is much safer than drum brake in hard braking condition.
Under such condition drum brake can lock up the rear wheel.
8. It has brake pad wear indicator which is not there in drum
brake
Disadvantages of disk brake
1. It is expensive compare to drum brake.
2. More skills require to operate disk brake compare to
drum brake that’s the reason why some people are not
comfortable with disk brake
3. If any air remains in disk brake system, it can cause
accident as the brake will not work effectively.
4. Disk brake assembly has more moving parts and much
complex than drum brake.
5. It requires lot of effort at maintenance front like brake
fluid (bleeding), change of brake pads etc compare to
drum brake.
