INTRODUCTION TO

MECHANICAL ENGINEERING

Rahul R
7592879176

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 CLUTCH

A clutch is a mechanical device which is used to engage and disengage the power
transmission between two shafts, such as the engine and the transmission system in a
vehicle

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 USES OF CLUTCH
1.Power Transmission Control
•Engages and disengages the engine's power from the drivetrain.
•Allows for smooth transmission of torque from the engine to the wheels.

2. Smooth Start and Stop

•Facilitates smooth starting of the vehicle by gradually transmitting power to the
wheels.
•Prevents sudden jerks when stopping.
3. Gear Shifting
•Enables smooth gear changes in manual transmission vehicles by disconnecting the
engine from the gearbox temporarily.
4. Overload Protection
•Protects mechanical components by slipping during overload conditions to prevent
damage.
5. Reduction of Wear and Tear
•Minimizes wear and tear on the engine and transmission by cushioning the torque
transfer
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TYPES OF CLUTCHES

1. Based on Operation:
Friction Clutches:
Single-Plate Clutch
Multi-Plate Clutch
Cone Clutch
Centrifugal Clutch
Dog Clutch

2. Based on Actuation:
Manual Clutch: Requires the driver to engage/disengage using a pedal.
Semi-Automatic Clutch: Uses sensors and actuators to assist operation.
Automatic Clutch: Fully automatic, used in modern vehicles .

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3. Based on Torque Transmission:
Electromagnetic Clutch: Uses electromagnetic force.
Hydraulic Clutch: Uses hydraulic fluid to transmit power.
Overrunning Clutch (Freewheel): Engages in one direction and disengages
in the opposite.

4. Specialized Clutches:
Sprag Clutch: Used in starter systems.
Fluid Coupling: Used in heavy machinery for smooth power transfer.
Slip Clutch: Used in agricultural equipment to prevent damage under
overload.

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Friction Clutches
These rely on friction to engage and disengage the drive.
(a) Single-Plate Clutch
Uses:
•Common in cars with manual transmission.
•Provides smooth engagement and disengagement during gear changes.
•Suitable for light to medium vehicles like sedans and hatchbacks.
(b) Multi-Plate Clutch
Uses:
•Used in high-performance vehicles and motorcycles requiring high torque
transmission.
•Found in racing cars, heavy-duty vehicles, and vehicles with limited space for a larger
clutch.
(c) Cone Clutch
Uses:
•Used in heavy vehicles, such as trucks and tractors, for high torque transmission.
•Found in marine engines and some industrial machinery for reliability under high
loads.
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(d)Centrifugal Clutch
Uses:
•Automatically engages with engine speed, making it ideal for scooters and mopeds.
•Used in small generators, lawnmowers, and chainsaws for ease of operation.

(e) Dog Clutch

Uses:
•Used in gearboxes for positive engagement without slippage, especially in manual
transmissions for gear selection.

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 COMPONENTS OF FRICTION CLUTCH

Flywheel: The flywheel is a heavy metal disc that is attached to the engine crankshaft.
It stores energy and helps to smooth out the power output of the engine.

Clutch plate: The clutch plate is a flat metal disc that is sandwiched between the
flywheel and the pressure plate. It is made of a material that has high friction, such as
friction material or carbon fiber.

Pressure plate: The pressure plate is a spring-loaded metal plate that presses the
clutch plate against the flywheel. It is held in place by bolt

Release bearing: The release bearing is a bearing that allows the clutch pedal to
move the pressure plate away from the flywheel. It is located on the end of the clutch
pedal linkage

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• When the clutch pedal is pressed, the release bearing pushes the pressure plate
away from the flywheel. This disengages the clutch and separates the engine from
the transmission.

• When the clutch pedal is released, the pressure plate moves back against the flywheel
and engages the clutch. This allows the engine to power the transmission and the
wheels.

Advantages:
•Simple and inexpensive to manufacture
•Easy to install and maintain
•Can be used in a wide variety of applications

Disadvantages:
•Prone to wear and tear in high-performance applications
•Can be noisy when engaging and disengaging
•Can cause vibration in the drivetrain

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 Centrifugal clutch
Multiplate Clutch

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Cone Clutch

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 Manufacturing /Production
Classification of Manufacturing process

- Forming ,Casting

- Machining

- Joining

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 Sand Casting
• Sand casting is a widely used manufacturing process for creating metal parts. It involves pouring molten
metal into a sand mold to form complex shapes.

• The mould is made of sand particles held together with an inorganic binding agent. After the metal has
cooled to room temperature, the sand mould is broken open to remove the casting.

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• The technique is the best option for manufacturing affordable and small parts in the automotive and
aerospace industries. The animation below shows the process.

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Cope and Drag: The top and the bottom part of a casting arrangement are called cope
and drag respectively. They are usually wooden frames

Riser: A riser is often called a feeder. It is a reservoir and a passage included in a metal
casting mould to avoid shrinkage of metal.

Runner: A runner is a channel with a reduced diameter used to allow the flow of molten
metal towards the cavity.

Mould: It is a cavity made out of a pattern (copy of the final desired cast) which is mostly
made of sand.

Core: The core in sand casting is a device inserted into the mould cavity to create
interior features in the casting such as holes.

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 Forging
• Forging is a manufacturing process in which metal is shaped by applying compressive forces, typically using
hammers, presses

• This process improves the mechanical properties of the material, making it stronger and more durable.

• Carbon, alloy, and stainless steel are frequently used in forging. Aluminum, brass, and copper, which are very
soft metals, can also be forged.

• The method can produce parts in large quantities and can be used to induce desired mechanical properties
to the finished product.

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 Rolling

• Rolling is a metal-forming process where a metal workpiece is passed through a pair of

rotating rollers to reduce its thickness, achieve uniformity, or produce desired cross-
sectional shapes.

• It is a widely used manufacturing technique in the metal industry

• This process is highly versatile and capable of producing a wide range of metal products,
such as sheets, plates, bars, and structural shapes, with precise dimensions and surface
finishes.

• The key principle is ensuring that the gap between the rollers is smaller than the metal's
initial thickness facilitating forward motion through the rollers.

• This process decreases the metal's thickness while increasing its length and breadth,
keeping the overall volume constant.
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 Extrusion
• Extrusion is a metal-forming process where a material is forced through a die to
produce a continuous cross-sectional shape.

• It is widely used for metals, plastics, and composites to create products with uniform
dimensions and complex geometries.

• In simple words, extrusion is a metalworking procedure that involves forcing metal

through a die hole under increased pressure to compress its cross-section.

• The extrusion process is widely used to manufacture bars, tubes, and sections of any
shape, either hollow or solid.

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 Welding
Welding is a manufacturing process used to join two or more materials (typically metals
or thermoplastics) by applying heat, pressure, or both. The materials being joined melt
and fuse together, sometimes with the addition of a filler material, to form a strong,
permanent bond.

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