· web viewthis allows the springs to extend and thus the pressure plate pushes the clutch plate...

Lecture (1) Vehicle Technology II

ClutchesIntroduction

A clutch is a machine member used to connect a driving shaft to a driven shaft so that the driven

shaft may be started or stopped at will, without stopping the driving shaft. The use of a clutch is mostly

found in automobiles. A little consideration will show that in order to change gears or to stop the vehicle, it

is required that the driven shaft should stop, but the engine should continue to run. It is, therefore,

necessary that the driven shaft should be disengaged from the driving shaft. The engagement and

disengagement of the shafts is obtained by means of a clutch which is operated by a lever.

Friction Clutches

A friction clutch has its principal application in the transmission of power of shafts and machines

which must be started and stopped frequently. Its application is also found in cases in which power is to be

delivered to machines partially or fully loaded. The force of friction is used to start the driven shaft from

rest and gradually brings it up to the proper speed without excessive slipping of the friction surfaces. In

automobiles, friction clutch is used to connect the engine to the drive shaft. In operating such a clutch, care

should be taken so that the friction surfaces engage easily and gradually bring the driven shaft up to proper

speed. The proper alignment of the bearing must be maintained and it should be located close to the clutch

as possible. It may be noted that :

1. The contact surfaces should develop a frictional force that may pick up and hold the load

with reasonably low pressure between the contact surfaces.

2. The heat of friction should be rapidly dissipated and tendency to grab should be at a

minimum.

3. The surfaces should be backed by a material stiff enough to ensure a reasonably uniform

distribution of pressure.

Material for Friction Surfaces

The material used for lining of friction surfaces of a clutch should have the following characteristics :

1. It should have a high and uniform coefficient of friction.

2. It should not be affected by moisture and oil.

3. It should have the ability to withstand high temperatures caused by slippage.

4. It should have high heat conductivity.

5. It should have high resistance to wear and scoring.

Considerations in Designing a Friction Clutch

The following considerations must be kept in mind while designing a friction clutch.

1. The suitable material forming the contact surfaces should be selected.

2. The moving parts of the clutch should have low weight in order to minimize the inertia load,

especially in high speed service.

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3. The clutch should not require any external force to maintain contact of the friction surfaces.

4. The provision for taking up wear of the contact surfaces must be provided.

5. The clutch should have provision for facilitating repairs.

6. The clutch should have provision for carrying away the heat generated at the contact surfaces.

7. The projecting parts of the clutch should be covered by guard.

Types of Friction Clutches

Though there are many types of friction clutches, yet the following are important from the subject

point of view :

1. Disc or plate clutches (single disc or multiple disc clutch),

2. Cone clutches, and

3. Centrifugal clutches.

Note: The disc and cone clutches are known as axial friction clutches, while the centrifugal clutch is

called radial friction clutch.

Single Disc or Plate Clutch

A single disc or plate clutch, as shown in

Fig 1, consists of a clutch plate whose both

sides are faced with a frictional material

(usually of Ferrodo). It is mounted on the hub

which is free to move axially along the splines

of the driven shaft. The pressure plate is

mounted inside the clutch body which is bolted

to the flywheel. Both the pressure plate and

the flywheel rotate with the engine crankshaft

or the driving shaft. The pressure plate pushes

the clutch plate towards the flywheel by a set

of strong springs which are arranged radially inside the body. The three levers (also known as release levers

or fingers) are carried on pivots suspended from the case of the body. These are arranged in such a manner

so that the pressure plate moves away from the flywheel by the inward movement of a thrust bearing. The

bearing is mounted upon a forked shaft and moves forward when the clutch pedal is pressed.

When the clutch pedal is pressed down, its linkage forces the thrust release bearing to move in

towards the flywheel and pressing the longer ends of the levers inward. The levers are forced to turn on

their suspended pivot and the pressure plate moves away from the flywheel by the knife edges, thereby

compressing the clutch springs. This action removes the pressure from the clutch plate and thus moves

back from the flywheel and the driven shaft becomes stationary. On the other hand, when the foot is taken

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off from the clutch pedal, the thrust bearing moves back by the levers. This allows the springs to extend and

thus the pressure plate pushes the clutch plate back towards the flywheel.

The axial pressure exerted by the spring provides a frictional force in the circumferential direction

when the relative motion between the driving and driven members tends to take place. If the torque due to

this frictional force exceeds the torque to be transmitted, then no slipping takes place and the power is

transmitted from the driving shaft to the driven shaft.

Design of a Disc or Plate Clutch

Consider two friction surfaces maintained in contact by an axial thrust (W ) as shown in Fig. 2

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T = Torque transmitted by the clutch,

p = Intensity of axial pressure with which the contact surfaces are held together,

r1 and r2 = External and internal radii of friction faces,

r = Mean radius of the friction face, and

μ = Coefficient of friction.

Consider an elementary ring of radius r and thickness dr as shown in Fig. 2(b).

We know that area of the contact surface or friction surface = 2π r.dr

Normal or axial force on the ring,∴δW = Pressure × Area = p × 2π r.dr

and the frictional force on the ring acting tangentially at radius r,

Fr = μ × δW = μ.p × 2π r.dr

Frictional torque acting on the ring,∴ Tr = Fr× r = μ.p × 2π r.dr × r = 2 π μ p. r2.dr

We shall now consider the following two cases:

1. When there is a uniform pressure,

2. When there is a uniform axial wear

1. Considering uniform pressure. When the pressure is uniformly (this theory apply for new clutch)

distributed over the entire area of the friction face as shown in Fig. 3 (a), then the intensity of pressure for

one pair of surface ,

p= Wπ [ (r1 )2−( r2 )2 ]

where W = Axial thrust with which the friction surfaces are held together.

We have discussed above that the frictional torque on the elementary ring of radius r and thickness

dr is Tr = 2π μ.p.r2.dr

Integrating this equation within the limits from r2 to r1 for the total friction torque.

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Total frictional torque acting on the friction surface or on the clutch, ∴ ( for 1 pair of surface of

contacts)

2- Considering uniform axial wear. The basic principle in designing machine parts that are subjected

to wear due to sliding friction is that the normal wear is proportional to the work of friction. The work of

friction is proportional to the product of normal pressure (p) and the sliding velocity (V). (for old clutch)

Therefore,

Normal wear Work of friction p.V or p.V = K (a constant) or∝ ∝p = K/V ...(i)

It may be noted that when the friction surface is new, there is a uniform pressure distribution over

the entire contact surface. This pressure will wear most rapidly where the sliding velocity is maximum and

this will reduce the pressure between the friction surfaces. This wearing-in process continues until the

product p.V is constant over the entire surface. After this, the wear will be uniform as shown in Fig. 3.

Let (p) be the normal intensity of pressure at a distance (r) from the axis of the clutch. Since the

intensity of pressure varies inversely with the distance, therefore

p.r = C (a constant) or p = C/r ...(ii)

and the normal force on the ring,

δW=p .2πr .dr=Cr×2 πr .dr=2πC .dr

∴ Total force acing on the friction surface,

W=∫r2

r1

2πCdr=2πC [r ]r2

r1=2πC (r1−r2)

C= W2π (r 1−r2)

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2. For a single disc or plate clutch, normally both sides of the disc are effective. Therefore a single

disc clutch has two pairs of surfaces in contact (i.e. n = 2).

3. Since the intensity of pressure is maximum at the inner radius (r 2) of the friction or contact surface,

therefore equation (ii) may be written as

pmax × r2 = C or pmax = C / r2

4. Since the intensity of pressure is minimum at the outer radius (r1) of the friction or contact

surface, therefore equation (ii) may be written as

pmin × r1 = C or pmin = C / r1

5. The average pressure ( pav) on the friction or contact surface is given by

pav=Total force on friction surface

Cross−sectional area of friction surface= Wπ [ (r1 )2−( r2 )2 ]

6. In case of a new clutch, the intensity of pressure is approximately uniform, but in an old clutch, the

uniform wear theory is more approximate.

7. The uniform pressure theory gives a higher friction torque than the uniform wear theory.

Therefore in case of friction clutches, uniform wear should be considered, unless otherwise stated.

Multiple Disc Clutch

A multiple disc clutch, as shown in Fig. 4, may be used when a large torque is to be transmitted. The

inside discs (usually of steel) are fastened to the driven shaft to permit axial motion (except for the last

disc). The outside discs (usually of bronze) are held by bolts and are fastened to the housing which is keyed

to the driving shaft. The multiple disc clutches are extensively used in motor cars, machine tools etc.

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Let n1 = Number of discs on the driving shaft, and

n2 = Number of discs on the driven shaft.

∴ Number of pairs of contact surfaces, n = n1 + n2 – 1

and total frictional torque acting on the friction surfaces or on the clutch,

T = n.μ.W.R

where R = Mean radius of friction surfaces

¿ 23 [ (r1 )3− (r2 )3

(r1 )2− (r2 )2 ] for uniform pressure ¿

r1+r2

2for uniformwear

Adjustment of toggle mechanismToggle mechanism is used to apply the required normal force (W). This mechanism consists of links and springs, in which links used to control the engagement or disengagement of the clutch. During engagement, the links are in position so that the spring is compressed to apply a normal force W, but during disengagement, the links are in position so that the spring is with their free length.Lets = spring numberk = spring stiffness (N/m)∆ = compressive deflection in the spring (m)

W = k*∆*sWorn layersDuring operation of the clutch, the pair of surfaces of contact are subjected to mechanical wear, then the thickness of the plates will decreases and the compressive deflection in the springs of toggle mechanism will relaxed, then the change in the thickness of plates will be equal to the relaxation in the springs.Let t = the change in the thickness of plates and l = layer thickness worn due to mechanical wear

t = 2*n*lIf ∆W represent the change in normal force ∆W = k*t*sDisengagement and engagement of clutch

1- Mass properties M1=masses attached to the driverM2 = masses attached to the driven shaftK1 = radius of gyration of m1

K2 = radius of gyration of m2

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I 1=m1k 12

I 2=m2 k22

where I1 and I2 are mass moment of inertia of m1,m2 about center of rotation

2- Torque

a- Driving tourqe

T1= inputpower/ steady state speed = I.P/W

b- Maximum torque for no slipping

To be in the safe side of design . the torque analysis from uniform wear theory be smaller than

torque from uniform pressure theory

c- Retarding torque T r

Is the maximum inertia torque induced in the driver shaft during engagement,max is the

maximum allowable deceleration in the driving shaft.

Tr=I1. 1

d- Acceleration torque T A

Is the maximum inertia torque induced in the driven shaft during engagement to accelerate the

driven by 2max is the maximum allowable acceleration in the driven shaft.

TA= I2. 2

e- Losses torque T L

Is the torque required to overcome the friction resistance in the driven shaft.

3- Engagement of plate clutch

Maximum deceleration of driving shaft 1

T=T1+Tr

α 1=T−T1

I 1

Maximum acceleration of driven shaft 2

T=TL+TA

α 2=T−T LI2

Speed and time duration during slipping

If w’ represent the speed at which slipping occur between inner and outer discs, t1 is the

time required to reach this speed. Assume that the driven shaft is at rest before

engagement

w’-w=-1t1 and also w’=-2t1 then

w’=α 2

α 2+α1w also t 1=

wα2+α 1

where α 2∧α 1substituted as absolute values.

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Acceleration after slipping α s

T1-TL=(I1+I2)α s

α s=T 1−T LI1+ I 2

Time duration to reach uniform speed t2

Is the time duration after slipping until reach the steady state speed of the driving shaft

t 2=w−w ’α s

Total time up to reach steady state speed

Tt=t1+t2

Example 1. Determine the maximum, minimum and average pressure in a plate clutch when the axial force

is 4 kN. The inside radius of the contact surface is 50 mm and the outside radius is 100 mm. Assume

uniform wear.

Example 2. A plate clutch having a single driving plate with contact surfaces on each side is required to

transmit 110 kW at 1250 r.p.m. The outer diameter of the contact surfaces is to be 300 mm. The coefficient

of friction is 0.4.

(a) Assuming a uniform pressure of 0.17 N/mm2; determine the inner diameter of the friction surfaces.

(b) Assuming the same dimensions and the same total axial thrust, determine the maximum torque that

can be transmitted and the maximum intensity of pressure when uniform wear conditions have been

reached.

Example 3. A single plate clutch, effective on both sides, is required to transmit 25 kW at 3000 r.p.m.

Determine the outer and inner diameters of frictional surface if the coefficient of friction is 0.255, ratio of

diameters is 1.25 and the maximum pressure is not to exceed 0.1 N/mm2. Also, determine the axial thrust

to be provided by springs. Assume the theory of uniform wear.

Example 4 A multi-disc clutch has three discs on the driving shaft and two on the driven shaft. The inside diameter of the contact surface is 120 mm. The maximum pressure between the surface is limited to 0.1 N/mm2. Design the clutch for transmitting 25 kW at 1575 r.p.m. Assume uniform wear condition and coefficient of friction as 0.3.

Hw.11. An engine is coupled to a rotating drum by a friction clutch which have a single disc faced on each

side with a ring of friction material. The inner and outer diameter of each ring are (240mm and 320mm) respectively ,=0.3 and the axial pressure on the disc is (1.3 KN). The engine develops a constant torque of (40 Nm),and its inertia is equivalent to that of a flywheel mass (25 kg) and radius of gyration (300 mm) .the drum has a mass of (55 kg) and its radius of gyration (400 mm) and the torque required to overcome friction is (7 Nm). If the clutch is engaged with the engine speed of (500 rpm) and the drum at rest.

Find the speed after slipping duration Find duration time of slipping Find total time to steady state

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