This document provides information about clutches, including:
1. Clutches allow the transmission of power from one rotating shaft to another while allowing the driven shaft to be engaged or disengaged at will without stopping the driving shaft.
2. Clutches are analyzed based on the torque transmitted, actuating force required, energy loss, and temperature rise. Uniform pressure and uniform wear conditions are considered in the analysis.
3. Common clutch types include friction clutches, which include plate or disc clutches, and the single dry plate clutch commonly used in automotive applications to connect the engine to the transmission.
This document provides information about clutches, including:
1. Clutches allow the transmission of power from one rotating shaft to another while allowing the driven shaft to be engaged or disengaged at will without stopping the driving shaft.
2. Clutches are analyzed based on the torque transmitted, actuating force required, energy loss, and temperature rise. Uniform pressure and uniform wear conditions are considered in the analysis.
3. Common clutch types include friction clutches, which include plate or disc clutches, and the single dry plate clutch commonly used in automotive applications to connect the engine to the transmission.
This document provides information about clutches, including:
1. Clutches allow the transmission of power from one rotating shaft to another while allowing the driven shaft to be engaged or disengaged at will without stopping the driving shaft.
2. Clutches are analyzed based on the torque transmitted, actuating force required, energy loss, and temperature rise. Uniform pressure and uniform wear conditions are considered in the analysis.
3. Common clutch types include friction clutches, which include plate or disc clutches, and the single dry plate clutch commonly used in automotive applications to connect the engine to the transmission.
This document provides information about clutches, including:
1. Clutches allow the transmission of power from one rotating shaft to another while allowing the driven shaft to be engaged or disengaged at will without stopping the driving shaft.
2. Clutches are analyzed based on the torque transmitted, actuating force required, energy loss, and temperature rise. Uniform pressure and uniform wear conditions are considered in the analysis.
3. Common clutch types include friction clutches, which include plate or disc clutches, and the single dry plate clutch commonly used in automotive applications to connect the engine to the transmission.
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Machine Design II
Prof. K.Gopinath & Prof. M.M.Mayuram
Indian Institute of Technology Madras CLUTCH Clutch Introduction A Clutch is i a machine member used to connect the driving s haft to a driven shaft, so th at the drive n shaft ma y be starte d or stopped at will, without stopping the driving shaft. A clutch thus provides an inte rruptible connection between two rotating shafts Clutches allow a high inertia load to be stated with a small power. A popularly known applic ation of clutch is in automotive vehic l es where it is used to connect the engine and the gear box. He re the clutch enables to crank and start the engine disengaging the transmission Dis en gage the transmission and change the gear to alter the torque on t he wheels. Clutches are als o used extens ively in production machinery of all types Mechanical Model Two inertias and traveling at the re spective angular velocities
Ia n d I 1 2 1 and
2 , and one of which may be zero , are to be brought to the same speed by engaging. Slippage occurs because the two elements are running at different speeds and energy is dissipat ed during actuation, result ing in temperature rise.
1
1
1
2 Clutch or b r ake Dyn a m i c Re pres ent a t ion o f Clu t ch o r Brake Figure 3.2.1 Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram Indian Institute of Technology Madras Animated Figure 3.2.2 To design analyze the performance of these devices, a knowledge on the following ar e required. 1. T he torque trans m itted 2. The actuating force. 3. The energy loss 4. T he temperature rise FRICTION CLUTCHES As in brakes a wide range of clutches are in use wherein they vary in their are in use their working principle as well the me thod of actuation and applicat ion of normal forces. The discussion here will be limited to mechanical type fri c tion Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram Indian Institute of Technology Madras clutches or more specifically to the pl ate or disc clutches also k nown as axial clutches Frictional Contact axial or Disc Clutches An axial c l utch is one in whic h the ma ting frictional members are moved in a direction parallel to the shaft. A typical cl utch is illustrated in the figure below. It consist of a driv ing disc connected to the drive shaft and a driven dis c co9nnected to the driven sha ft. A friction plate is attached to one of the members. Actuating spring keeps both the members in contact and power/motion is transmitted from one mem ber to the other. Wh en the power of motion is to be interrupted the driven disc is mov ed axially creating a gap between the members as shown in the figure. Figure 3.2.3 Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram Indian Institute of Technology Madras Flywheel Clutch pl ate Pressure plate Clutch cover Diaphragm spr i ng to tra n s m i s s i o n Throw out Bearing Animated Figure 3.2.4 METHOD OF ANALYSIS The torque that can be transmitted by a clutch is a fu nction of its geometry and the magnitude of the actuating force appl ied as well the condition of contact prevailing between the member s. The applied force can keep the members together with a uniform pr essure all over its cont act area and t h e cons equent analys is is based on uniform pressure condition Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram Indian Institute of Technology Madras Uniform Pressure and wear Howev e r as the time progresses some w ear takes place between the contacting members and this may alter or vary th e contact pressure appropriately and uniform pressure condition may no longer prevail. Hence the analysis her e is based on uniform wear condition Elementary Analy s is Assuming uniform pressure and cons idering an elemental area dA dA = 2
.r d r The normal force on this elemental area is dN 2 . r. dr. p =
The frictional force dF on this area is therefore dF f . 2 . r. dr. p =
Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram Indian Institute of Technology Madras < <> d o F r d i dr lining A single-Surface Axial Disk Clutch Figure 3.2.5 Now the t o rque that can be transmitted by this elemental are is equal to the frictional force times the moment arm about the axis that is the radius r i.e. T = dF. r = f.dN. r = f.p .A.r = f.p.2.
.r . dr .r The total torque that could be transmitted is obtained by integrating this equation between the limits of inner radius ri to the outer radius ro r o 2 23 T 2 pf r d r p f ( r r ) o i 3 r i = =
3 Integrating the normal force between the sa me limits we get the actuating force that need to be applied to transmit this torque. Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram Indian Institute of Technology Madras () a 22 ao i r o F 2 prdr r i Fr r =
=
. p Equation 1 and 2 can be combined together to give equation for the torque 33 o i a 22 oi (r r ) 2 Tf F . 3 (r r )
=
Uniform Wear Condition According to some established theorie s the wear in a mechanical system is proportional to the PV fact or where P refers the contact pressure and V the sliding velocity. Based on this for the case of a plate clutch we can state The constant-wear rate R w is assumed to be proportional to the product of pressure p and veloc i ty V. R w = pV= constant And the velocity at any point on t he face of the clutch is Vr . =
Combining these equation, assumi ng a constant angular velocity
pr = constant = K The largest pressure p max must then occur at the smallest radius r i , max i Kp r = Hence pressure at any point in the contact region i max r pp r = Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram Indian Institute of Technology Madras In the previous equations substituting th is value for the pressure term p and integrating between th e limits as done earlier we get the equation for the torque transmitted and the actuating force to be applied. I.e The axial force F a is found by substituting i max r pp r = fo r p. and integrating equat ion dN 2 p rdr =
rr oo r i F 2 prdr 2 p rdr 2 p r ( r r ) ma x m ax i o i r rr ii
= = =
Similarly the Torque r o 22 Tf 2 p r r d r f p r ( r r m a xi m a xi o i r i = =
) Substituting the values of actuati ng force Fa The equation can be given as (r r ) oi Tf F . a 2 + = Single plate dry Clutch Automotive application The clutch used in aut omotive applications is generally a single plate dry clutch. In this type the clutc h plate is inter posed between the flywhe el surface of the engine and pressure plate. Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram Indian Institute of Technology Madras Flywheel Friction planes Clutch plate (driven disk) Pre ssure plate Pre ssure spring Hou s ing Release bearing Engine crankshaft To release To transmission Figure 3.2.6 Single Clutch and Multiple Disk Clutch Basically, the clutch needs three parts. These are the engine flywheel, a friction disc called the clutch plat e and a pressure plate. When the engine is running and the fly w heel is rot a ting, the pressure plate also rotates as the pressure plate is attached to the fly w heel. The friction di sc is located between the two. W h en Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram Indian Institute of Technology Madras the driver has pushed down th e clutch pedal the clutch is releas ed. This action forces the pressure plate to move away from the friction disc. T h ere are now air gaps between the flywheel and the friction disc, and b e tween the friction disc and the pressure plate. No power c an be transmi tted through the clutch. Operation Of Clutch When the driver releases the clutch pedal, power c an flow through the clutch. Springs in the clutch force the pressure pl at e against the friction disc. This action clamps the friction dis k tightly bet ween the flywheel and the pressu re plate. Now, the pressure plate and friction disc rotate with the flywheel. As both side surfaces of the c l utch plat e is used for transmitting the torque, a term N is added to inclu de the number of surfaces used for transmitting the torque By rearranging the terms the equations can be modified and a more general form of the equation can be written as T N . f .F .R am = T is the torque (Nm). N is the number of frictional discs in contact. f is the co efficient of friction F a is the actuating force (N). R m is the mean or equivalent radius (m). Note that N = n1 + n2 -1 Where n1= number of driving disc s n2 = number o f driven discs Values of the actuating fo rce F and the mean radius for the two conditions of analys is are summari zed and shown in the table m r Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram Indian Institute of Technology Madras Clutch Construction Two basic types of clutch are the co il-spring clutch and the diaphragm-spring clutch. The difference between them is in the type of spring used. The coil spring clut ch shown in left Fig 3.2.6 uses coil springs as pressure springs (only two pressure spring is shown). The clut c h shown in right figure 3.2.6 us es a diaphragm spring. Figure 3.2.6 The coil-spring clutch has a series of coil springs set in a circle. At high rotational speeds, problems can arise with multi coil spring clut ches owing to the effects of centrifugal forc es both on the s p ring them selves and the lever of the release mechanism. These problems are obviated when di aphragm type springs are used, and a number of other advantages are also experienced Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram Indian Institute of Technology Madras Clutch or Driven Plate More comple x arrange ments are used on the driven or clutch pl ate to facilitate smooth function of the clutch The friction disc, more generally k nown as the clutch plate, is shown partly cut away in Fig. It consists of a hub and a plate, with facings attached to the plate. Figure 3.2.7 First to ensure that the drive is taken up progressively, the centre plate, on which the friction facings are mounted, consists of a series of cushion s p rings whic h is crimped radially so t hat as the clampi ng force is applied to the facings the crimping is progressiv e ly squeez ed flat, enabling gradual trans fer of the force On the rel ease of the clamping force, the plate springs back to its origina l position crimped (wavy) state Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram Indian Institute of Technology Madras This plate is also slotted so that the heat generated does not cause distortion that would be liable to occur if it we re a plain plate. This plate is of course thin to keep rotational inertia to a minimum. Plate to hub Connection Secondly the plate and it s hub are entirely separate co mponents, the drive being transmitted from one to the other through coil springs interposed between them. These springs are carried within rectangular holes or slots in the hub and plate and arranged with their axes aligned appropriately for transmitting the drive. These dampening springs are heavy coil sp rings set in a circ le around the hub. The hub is driven through these springs. They help to smooth out the torsional vibration (the power pulses from the engi ne) so that the power flow to the transmission is smooth. In a simple design all the springs may be identical, but in more sophisticated designs the are arranged in pairs located diametrically opposite, each pair having a different rate and different end clearances so that t heir role is progressive providing increasing spring rate to cater to wider torsional damping The clutch plate is assembled on a splined shaft that carries the rotary motion to the transmission. This shaft is called the clutch shaft, or transmission input shaft. This shaft is connected to the gear box or forms a par t of the gear box. Friction Facings or Pads It is the friction pads or facings which ac tually transmit the power from the fly wheel to hub in the clutch plate and from there to th e out put shaft. There are Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram Indian Institute of Technology Madras grooves in both sides of the friction-di sc facings. T hese grooves prevent the facings from sticking to the flywheel face and pressure plate when the clutch is disengaged. The grooves break any va cuum that might form and caus e the facings to stick to the flywheel or pressure plate. The facings on many friction discs are made of cotton and asbestos fi bers woven or molded together and impregnated with resins or other binding agents. In many fricti on discs, copper wires are woven or pressed into the facings to giv e them ad ded strength. Howev e r, asbestos is being replaced with other materials in many clutches. Some friction discs have ceramic-metallic facings. Such discs are widely used in multiple plate clutches The minimize the wear problem s, all the pl ates wi l l be enclosed i n a covered chamber and immersed in an oil medium Such clutc hes are called wet clutches Multiple Plate Clutches Figure 3.2.8 The properties of the fricti onal lining are important fact ors in the design of the clutches Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram Indian Institute of Technology Madras Typical characteristics of some widely us ed friction linings are given in the table Table Properties of co mmon clutch/ Brake lining materials Friction Mat e rial Against Steel or Cl Dynamic Coefficient of Friction Maximum Pressure Maximum Temprerature Molded Woven Sintered metal Cast iron of hard steel 0. 25- 0 .45 0. 25- 0 .45 0. 15- 0 .45 0.15-0.25 0.06-0.09 0. 08- 0 .10 0.05-0.08 0.03-0.06 1030-2070 345-690 1030-2070 69 0- 720 204-260 204-260 232-677 26 0 dry in oil KPa o C Table 3.2.1