Ma ee Reet Friction Clutches’ 1 CLUTCHES The clutch is a mechanical device, which is used to connect or disconnect the source of power from the ‘remaining parts of the power transmission system at the will of the operator. An automotive clutch ‘can permit the engine to run without driving the car. This is desirable when the engine is to be started or stopped, or when the gears are to be shifted. Very often, three terms are used together, namely, couplings, clutches and brakes. There is ‘a basic difference between the coupling and the clutch. A coupling, such as a flange coupling, is ‘2 permanent connection, The driving and driven shafts are permanently attached by means of ‘coupling and it is not possible to disconnect the shafis, unless the coupling is dismantled. On the ‘ther hand, the clutch can connect or disconnect the driving and driven shafis, as and when required by the operator. Similarly, there is a basic difference between initial and final conditions in clutch and brake operations. In the operation of clutch, the conditions are as follows: (@ Initial Condition The driving member is rotating and the driven member is at rest. (i) Final Condition Both members rotate at the same speed and have no relative motion. Im the operation of brake, the conditions are as follows: . Chapter 1 1 (@ Initial Condition One member such as the brake drum is rotating and the braking member such as the brake shoe is at rest, 5) Final Condition Both members are at rest and have no relative motion, Clutches are classified into the following four groups: (@ Positive contact Clutches They include square jaw clutches; spiral jaw clutches and toothed clutches, In these clutches, power transmission is achieved by means of interlocking of jaws or teeth. Their main advantage is positive engagement and once coupled, they can transmit lange torque with no slip. (Gi) Friction Clutches They include single and multi-plate clutches, cone clutches and centrifugal clutches. In these clutches, power transmission is achieved by means of friction between contacting surfaces, This chapter is restricted to. friction clutches. Gi Electromagnetic Clutches They _ include magnetic particle clutches, magnetic hysteresis clutches and eddy current clutebes. In these clutches, power transmission is achieved by means of the magnetic field. These clutches have many advantages, such as rapid response time, ease of control, and smooth stars and stops.Ue dee Friction Clutches 499 (io) Fluid Clutches and Couplings In these clutches, power transmission is achieved by means of hydraulic pressure, A fluid coupling provides ‘extremely smooth starts and absorbs shock. ‘The simplest form of positive contact clutches is the square jaw clutch as shown in Fig. 11.1. It consists of two halves carrying projections or jaws. ‘One clutch half is fixed and the other can move along the axis of the shaft over either a feather key or splines by means of shift lever. During the ‘engagement, the jaws of the moving half enter into the sockets ofthe mating half. The engaging surfaces ‘of jaw and socket form a rigid mechanical junction. Jaw clutches can be used t0 connect shafts, when the driving shaft is stationary or rotating at very low ‘velocity. There are two types of jaws, namely, square and spiral. The spiral jaws can be engaged a slightly higher speed without clashing, Frequent engagement results in wear of jaws. The jaw clutches have the following advantages: (@) They do not slip and engagement is positive. (b) No heat is generated during engagement or disengagement St Jaw Socket ‘shut ever Fig. 1A Square Jaw Clute ‘The jaw clutches have the following drawbacks: (@) Jaw clutches can be engaged only when both shafts are stationary or rotate with very small spoed difference, (b) They cannot be engaged at high speeds because engagement of jaws and sockets results in shock, In general, positive contact clutches are rarely used as compared with friction clutches. However, they have some important applications where synchronous operation is required like power presses and rolling mils. ‘A single plate friction clutch consisting of two flanges is shown in Fig. 11.2, One flange is, rigidly keyed to the driving shaft, while the other is connected to the driven shaft by means of splines, The splines permit free axial movement of the driven lange with respect to the driven shaft This axial movement is essential for engagement and disengagement of the clutch. The actuating force is provided by a helical compression spring, ‘which forces the driven flange to move towards the driving flange. Power is transmitted from the driving shaft to the driving flange by means of the key. Power is then transmitted from the driving flange to the driven flange by means of frictional force. Finally, power is transmitted from the driven flange to the driven shaft by means of the splines. Since the power is transmitted by means of frictional force between the driving and driven Friction ting Actuating ‘spring Fig. 11.2. Single Plate Clutch flanges, the clutch is called ‘friction’ clutch. In ‘order to disengage the elutch, a fork is inserted in the collar on the driven flange to shift it axially to the right side. This relieves the pressure between the driving and the driven flanges and no torque can be transmitted. In the working condition, the clutch is in an engaged position under the action of spring force. Levers or forks are operated to “disengage™ the clutch.The McGraw-Hill companies 450 Design of Machine Elements ‘The main advantages of friction clutch are as_-—_-D = outer diameter of friction disk (mm) follows: = inner diameter of friction disk (mm) (i) The engagement is smooth. = intensity of pressure at radius r (Nim?) (Gi) Slip occurs only during engaging operation _P = total operating force (N) and once the clutch is engaged, there is, = torque transmitted by the clutch (N-mm) no slip between the contacting surfaces ‘Therefore, power loss and consequent heat generation do not create problems, unless the ‘operation requires frequent starts and stops ii) In certain cases, the friction clutch serves as a safety device. It slips when the torque transmitted through it exceeds 2 safe value ‘This prevents the breakage of parts in the transmission chain, Depending upon the number of friction surfaces, the friction clutches are classified as single-plate Fig 113 Friction Disk ‘or multi-plate clutches. Depending upon the shape The intensity of pressure p at radius r may be of the friction material, the clutches are clasified constant or may be variable as disk clutches, cone clutches or expanding shoe "Consider an elemental ring of radius rand radial clutches, thickness ab-as shown in Fig. 11.4. For this ring, clemental area 500 KPa Step Inside dismeter of disks M,=75 N-m = 75 000 Nemmn ‘Pa ~ 500 kPa = 500% 10°? MPa = 0.5 N fmm? From Eq. (11.10), ups 7 +a) 1 ig observed from the above expression that there are two unknowns d and 2, and one equation, Tt cannot be solved unless we make some assumption, We will assume that the elutch is transmitting maximum torgue, AS explained in Example 11.4, the condition for this objective is writen as, 0877 or d= 0.577 D=0.S77(100) 7.7 or $8 mm Step Clamping force For Fg. (11.6), _ apd pa BR yg) 20989 100 - 58) 1913.23N Step HI Reguired number of disks From Eq, (11.10) 4M, 4(75 000) uP(D+ ad) — G.KI913.23000+58) 9207 10 Number of disks =2 +1 = 10+ ‘We will use 6 plane steel disks and 5 steel disks With attached asbestos lining. 114 FRICTION MATERIALS For light loads and low speeds, wood, cork and Teather are used as friction materials. The present trend for high speeds and heavy loads has given a stimulus to the development of new friction materials, which are capable of withstanding severe service conditions. The desirable properties of a good friction material are a follows: () It should have high coefficient of friction. (Gi) The coefficient of friction should remain constant over the entire range of tempers tures encountered in applications (ii) Ttshould have good thermal conductivity Gv) Iishould remain unaffected by environmental conditions like moisture, or dirt particlesThe McGraw-Hill companies 460 _Design of Machine Elements (9) It should have high resistance to abrasive and adhesive wear, (vi) It should have good resilience to provide g00d distribution of pressure at the contacting surfaces, ‘The coefficient of frietion depends upon a number of factors, They include materials of contacting surfaces, surface finish, surface temperature, rubbing speed, foreign particles on rubbing surfaces and atmospheric conditions like moisture. There are two types of friction materials in ‘common use—asbestos-base and sintered metals There are two types of asbestos friction ‘materials—woven and moulded. A woven asbestos friction disk consists of asbestos fibre woven around brass, copper or zine wires and impregnated with rubber or asphalt, They have an endless circular weave, which increases the centrifugal bursting strength, Moulded asbestos friction disks are prepared from the wet mixture of brass chips ‘and asbestos, which is poured into the mould and teiven the shape of the disk, The mixture is then heated and pressed for a specific curing time. The difference between woven and moulded asbestos ‘materials is as follows: (@ Woven material is flexible, while moulded asbestos is rigid. (ii) Woven material has higher coefficient of friction, ii) Woven material conforms more readily to clutch surface while moulded materials take longer time to wear inthe seat iv). Woven materials are not only costly, but also wear ala faster rate, resulting in high eost in the long run, Asbestos material, whether woven or moulded, is an organic material and is subject to destruction by heat at comparatively low temperature. Sintered-metal friction materials solve this, difficulty. There are two varieties of friction disks made from sintered motals—bronze-base and iron- base, depending upon the major constituent. The advantages of sintered-metal friction disks are as follows: (i) They have higher wear resistance. i) They can be used at high temperatures. ii) The coefficient of friction is constant over a ‘wide range of temperature and pressure. Gv) They are unaffected by environmental conditions, such as dampness, salt water or fungi Sintered-metal friction materials offer an excellent design with lighter, cheaper and compact construction, The maximum permissible intensity of pressure for woven and moulded asbestos materials is 0.3 Nimm? and 1.0 Nimm? respectively, while for sintered metals it can be taken between | and 2 Nimm’. The values of coefficient of friction for different combinations are given in Table 11.1 Table 111 Coefcien of friction ‘Contacting surfaces Coicient of ction Wer ‘Dry Woven asbestos cast iron 01-02 03-06 Moulded asbestos —cast iron 0.08-0.12 0.2-05 Bronze-hasesinteredmetal— 0,050.1 0,1-0.4 cast iron Bronze-base sintered metal 0.05-0.1 0.1-03 It has been found that if asbestos dust is inhaled, it may lead to cancer. The body cells which come in contact with asbestos particles are agitated and develop into cancer cells. Lung cancer is common among operators working in atmospheres of asbestos dust. There are federal regulations ina number of countries, which prohibit the use of asbestos in clutch or brake linings, Nowadays, metallic or semi-metallie fibres or powder is used in place of asbestos fibres. Modern fiction lining consists of four basic ingredients, namely, fibres, filler, binder and friction modifiers. Fibres provide rigidity and strength for the friction lining. Nowadays, steel wool or aramid is used as fibre material instead of asbestos. A filler fills the space between the fibres and extendTT Le eRe etd Friction Clutches $61 the lining life, Filler materials are barytes, clay ‘and calcium carbonate, In case of metallic lining, fine metal power is used as filler material. Binder isa glue that holds the lining ingredients together. Phenolformaldchyde is extensively used as binder ‘material, Friction modifier improves. trictional and wear properties, Brass and zine particles are added as frietion modifiers to control the abrasive properties of the lining. 115 CONE CLUTCHES ‘A cone clutch, as shown in Fig, 11.10, consists of inner and outer conical surfaces. The outer cone is keyed to the driving shaft, while the inner cone is free to slide axially on the driven 4; Cone Driving ‘hot [Engaging ‘peng Driven, shat Fig. 1110 Cone Clutch shaft due to splines. The axial force required to engage the clutch is provided by means of helical compression spring. In engaged position, power is transmitted from the driving shaft to the ‘outer cone by means of the key. Power is then ‘transmitted from the outer cone to the inner cone bby means of friction. Finally, power is transmitted from the inner cone to the driven shaft by means of the splines. In order to disengage the clutch, a fork is inserted in the shifting collar to shift it axially towards right side. This releases pressure between inner and outer cones and no torque ean be transmitted. Leather, cork or asbestos are used forthe friction lining on the inner cone. The conical surface results in considerable friction force even with a small engaging force due 10 the wedge action. The recommended semi-cone angle (a) is 12.5°, The cone clutches are simple in construction and easy to disengage. Their main drawback isthe strict requirement for the coaxiality of two shafts “The equations for the torque transmitting capacity fof the cone clutch are derived in a manner similar to that of a single plate clutch. The dimensions of the fiction cone are shown in Fig. 1111. An ‘elemental frustum of the cone bounded by circles ‘of radii rand (r dr) is considered for the purpose of analysis, Figure 11.12(@) shows this elemental frustum of cone, For this fustum, p (ares) p 5A~ rm) sing Fig 141 “i parcose a padsna Aw | eran Bes ies ® o) Fig 1112