Chapter 16
Clutches & Brakes
16 Clutches, Brakes
Chapter 16-1 Static Analysis of Clutches and Brakes
Outline 16-2 Internal Expanding Rim Clutches and Brakes
16-3 External Contracting Rim Clutches and Brakes
16-4 Band-Type Clutches and Brakes
16-5 Frictional-Contact Axial Clutches
16-6 Disk Brakes
16-7 Cone Clutches and Brakes
16-8 Energy Considerations
16-9 Temperature Rise
16-10 Friction Materials
16-11 Miscellaneous Clutches and Couplings
16-12 Flywheels
https://www.youtube.com/watch?v=devo3kdSPQY (7 min)
https://www.youtube.com/watch?v=auQgOtveQi0 (8 min)
https://www.youtube.com/watch?v=6BaECAbapRg (2 min)
https://www.youtube.com/watch?v=pqF-aBtTBnY (4min)
Introduction
• A simplified dynamic representation of
a friction clutch or brake is : two
inertias, I1 and I2, traveling at the
respective angular velocities ω1 and
ω2, one of which may be zero in the
case of brakes, are to be brought to
the same speed by engaging the
clutch or brake.
• In analyzing the performance of these devices we shall be interested in:
The actuating force
The torque transmitted
The energy loss
The temperature rise
• The torque transmitted is related to the actuating force, the coefficient of
friction, and the geometry of the clutch or brake.
4
An Internal Expanding Centrifugal-acting Rim Clutch
Fig. 16–3
Courtesy of the Hilliard Corporation.
5
Internal Friction Shoe Geometry
deformation perpendicular to AB is
The deformation perpendicular to the rim
Thus, the deformation, and consequently the pressure, is
proportional to sin ɵ. In terms of the pressure at B and where the
pressure is a maximum, this means
6
Fig. 16–4
Pressure Distribution Characteristics
• Pressure distribution is sinusoidal
• For short shoe, as in (a), the largest
pressure on the shoe is pa at the end
of the shoe
• For long shoe, as in (b), the largest
pressure is pa at a = 90º
7
Fig. 16–6
Force Analysis
differential normal force dN
Fig. 16–7
The actuating force F must balance these moments. Thus
Self-locking condition
Force Analysis
The torque T applied to the drum by the brake shoe is the
sum of the frictional forces f dN times the radius of the drum
The hinge-pin reactions are found by taking a summation of the
horizontal and vertical forces
Force Analysis
The direction of the frictional forces is reversed if the rotation is reversed. Thus, for counterclockwise rotation
the actuating force is
Example 16–2
Fig. 16–8
Solution:
Example 16–2
Fig. 16–9
An External Contracting Clutch‐Brake
Fig. 16–10 Fig. 16–11
Courtesy of Twin Disc Clutch Company.
Force Analysis for External Contracting Shoes
External Contracting Rim
• The moments of the frictional and • The distance a to the pivot is
normal forces about the hinge pin chosen by finding where the
are moment of the frictional forces Mf is
zero.
• The actuating force must be large • Mislocating the pivot results in
enough to balance both moments: unsymmetrical wear, retiring the
shoe lining, hence the shoe, sooner.
• The torque is
• The horizontal and vertical reactions
at the hinge pin are found in the
same manner as for internal
expanding shoes.
• Pressure-distribution relation of a
symmetric pivot shoe is
where pa is the maximum value of
p(θ).
19
Band-Type Clutches and Brakes
• Because of friction and the rotation of the drum, the
actuating force P2 is less than the pin reaction P1.
• Summing up forces in the vertical direction, we have
• Summing the forces in the horizontal direction gives
• As result,
• The pressure is proportional to the tension in the
band as
The maximum pressure pa will occur at the toe and has
the value
20
Notation for Band‐Type Clutches and Brakes
Fig. 16–13
Frictional‐Contact Axial Single‐Plate Clutch
Frictional‐Contact Axial Multi‐Plate Clutch
Fig. 16–14
Frictional-Contact Axial Clutches :
Uniform Wear
• An axial clutch has the mating frictional members
being moved in a direction parallel to the shaft.
• Figure shows a friction disk having an outside
diameter D and an inside diameter d. We are
interested in obtaining the axial force F
necessary to produce a certain torque T and
pressure p.
• After initial wear has taken place and the disks have worn down to a
point where uniform wear is established, with wear being constant
from place to place.
• With pr constant, the total normal force
• The torque is found by integrating the product of the frictional force
and the radius
23
Frictional-Contact Axial Clutches :
Uniform Pressure
• When uniform pressure can be assumed over the area of the disk,
the actuating force F is simply the product of the pressure and the
area.
• The torque is
• The method of Buckingham uses three dimensionless groups
, ,and ,and contracts
• Given the uncertainties in the actual coefficient of friction and the
certainty that new clutches get old, there is little reason to use
anything but the analyses assuming uniform wear.
24
Disc Brakes
https://www.youtube.com/watch?v=KJ0koDXk6PY (3 min)
https://www.youtube.com/watch?v=0ykCdaRzn5g (10 min)
https://www.youtube.com/watch?v=MAuVDB-G-HQ (Part 1 - 5 min)
https://www.youtube.com/watch?v=bGKJOICWmFQ (Part 2 – 3 min)
Video quiz: https://www.youtube.com/watch?v=URqf-GyqUU4
25
Disc Brakes
• When drum brakes are used as vehicle brakes, only a slight
change in the coefficient of friction will cause a large change
in the pedal force required for braking. The disk brake has no
self-energization, and hence is not so susceptible to changes
in the coefficient of friction.
• The actuating force and the friction torque of an annular-pad
brake are given by
Uniform wear :
Uniform pressure :
Uniform wear :
Uniform pressure :
26
Cone Clutches and Brakes
• A cone clutch consists of a cup
keyed or splined to one of the
shafts, a cone that must slide
axially on splines or keys on the
mating shaft, and a helical
spring to hold the clutch in
engagement.
• The cone angle α and the
diameter and face width of the
cone are the important
geometric design parameters.
https://www.youtube.com/watch?v=DBihQcNCEO0 (3 min)
https://www.youtube.com/watch?v=s-BL3dkaChw (1min)
27
Uniform Wear
With the pressure relation being
The operating force will be
The torque is
Uniform Pressure
Energy Considerations
• When the rotating members of a machine are caused to stop by
means of a brake, the kinetic energy of rotation must be absorbed
by the brake in the form of heat.
• The clutching operation is completed at the instant in which the two
angular velocities become equal.
• With a constant clutch torque, the rate of energy-dissipation during
the clutching operation is
• The total energy dissipated during the clutching operation or braking
cycle is
30
Temperature Rise
• The temperature rise of the clutch or brake assembly is
• At initial temperature T1 in an environment of temperature
T∞, the Newton’s cooling model is expressed as
• The heat-dissipation capacity of disk brakes has to be planned to avoid reaching
the temperatures of disk and pad that are detrimental to the parts. The rate of
heat transfer is described by another Newtonian equation:
31
Friction Materials
• A brake or friction clutch should have the following lining material
characteristics
High and reproducible coefficient of friction
Imperviousness to environmental conditions, such as moisture
The ability to withstand high temperatures, together with good thermal conductivity
and diffusivity, as well as high specific heat capacity
Good resiliency
High resistance to wear, scoring, and galling
Compatible with the environment
Flexibility
32
Friction Materials (Cont.)
33
Miscellaneous Clutches and Couplings
• The square-jaw clutch is a positive-contact
clutch. The following characteristics:
They do not slip.
No heat is generated.
They cannot be engaged at high speeds.
Sometimes they cannot be engaged when both shafts
are at rest.
Engagement at any speed is accompanied by shock.
• To provide a longer period of time for shift action
during engagement, the jaws may be ratchet-
shaped, spiral-shaped, or gear-tooth-shaped.
• Devices such as linear drives or motor-operated
screwdrivers must run to a definite limit and then
come to a stop.
• An overrunning clutch or coupling permits the
driven member of a machine to “freewheel” or
“overrun” because the driver is stopped or
because another source of power increases the
speed of the driven mechanism.
34
Flywheels https://www.youtube.com/watch?v=EMazLuxpzxE
• The equation of motion for a flywheel is
where Ti is considered positive and To negative, and where and are the
first and second time derivatives of θ, respectively.
• If the work output of the flywheel is greater than the work input to the
flywheel , the load uses more energy than has been delivered to the
flywheel and so ω2 will be less than ω1.
• It is convenient to define a coefficient of speed fluctuation as
where ω is the nominal angular velocity, given by
• The change in kinetic energy is
35
Flywheels (Cont.)
• Punch-press torque demand often
takes the form of a severe impulse
and the running friction of the drive
train. • During the interval from t1 to t2 the
motor accelerates the flywheel
• Punch presses can have the motor
and flywheel on one shaft, then, according to I = TM
through a gear reduction, drive a
slider-crank mechanism that carries
• For the deceleration interval when
the punching tool. The work done is
the motor and flywheel feel the
given by
punch torque on the shaft as TL
• Having T2 the flywheel inertia is
• An induction motor has a linear
torque characteristic T = aω + b in
the range of operation. The
constants a and b can be found
from the nameplate speed ωr and
the synchronous speed ωs :
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