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Clutches, Brakes, Couplings

and Flywheels

ME-305 Mechanical Engineering Design II

Introduction
Clutch;
Clutch is a device that transfers
1
power
The thee animations show
1. Clutch is not engaged
2. Clutch is partially engaged
3. Clutch is fully engaged

ME-305 Mechanical Engineering Design II

CH # 16

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Brake;
A brake is a device for slowing or stopping the
motion
to keep it from starting to move again.
The kinetic energy lost by the moving part is
usually translated to heat by friction.

ME-305 Mechanical Engineering Design II

Introduction

ME-305 Mechanical Engineering Design II

Introduction

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Types

Rim types with internal expanding shoes

Rim types with external contracting shoes
Band type
Disk or axial type
Cone type
Miscellaneous types

ME-305 Mechanical Engineering Design II

Introduction
Parameters to analyze

ME-305 Mechanical Engineering Design II

Introduction

The actuating force

The torque required
The energy loss
The temperature rise

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Internal expanding clutch and

brake is shown in figure
The sub-types are;

Expanding-ring
Centrifugal
Magnetic
Hydraulic and
Pneumatic

Consider a pressure P acting on the

element area located at .
Consider the maximum pressures is pa
which is located at a.
The shoe deforms by an angle d
It can then be shown that the elemental
normal force is then given by;

ME-305 Mechanical Engineering Design II

16-2 Internal expanding rim

clutches and brakes

ME-305 Mechanical Engineering Design II

16-2 Internal expanding rim

clutches and brakes

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ME-305 Mechanical Engineering Design II

16-2 Internal expanding rim

clutches and brakes
Forces.
We are interested in
Actuating force F
Torque T
Pin reactions Rx & Ry

Taking moment of the frictional force about pivot point

Where

Then

4
2
4
And similarly the moment of the normal force is

2
Note:

ME-305 Mechanical Engineering Design II

16-2 Internal expanding rim

clutches and brakes

2
2
2

1
2

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If 1 = 0o
2
2

1
4

The actuating force acting on the shoe is (taking moment

about the pivot point);
0

ME-305 Mechanical Engineering Design II

16-2 Internal expanding rim

clutches and brakes

If drum is rotating in
reverse

And Torque is due to the friction force (tangential

component) and is given by;

Reactions are calculated by summing forces in x and y

directions ( for c.w and for c.c.w):

Where

ME-305 Mechanical Engineering Design II

16-2 Internal expanding rim

clutches and brakes

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The governing equations are valid when

The coordinate system has its origin at the center of the
drum. The +ve x-axis is taken through the hinge pin.
The +ve y-axis is always in the direction of the shoe.
The pressure is proportional to the distance from the
pivot point.
The centrifugal effects are neglected
The shoe is rigid
The coefficient of friction is not changing

Drum brakes have a natural "selfapplying" characteristic, known as "selfenergizing.

The rotation of the drum can drag the
shoe into the friction surface, causing
the brake to bite harder, which increases
the force holding them together.
This effect occurs on one shoe.
Less actuating force is then required
The forces are different on each brake
shoe resulting in one shoe wearing
faster.

ME-305 Mechanical Engineering Design II

Self-energizing action

ME-305 Mechanical Engineering Design II

To Remember

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ME-305 Mechanical Engineering Design II

Self-energizing action
Also self-energization can be obtained
from the equation
If
then zero actuating force is
required
Due to the self-energizing action, the
brake mechanism and brake shoes
should be properly designed (Serve
and Non-serve brake system).
Video

More information on this topic: TechOne: Automotive Brakes by Jack Erjavec,

Cengage Learning, 01-Sep.-2003

ME-305 Mechanical Engineering Design II

Example 16-2
The brake shown in Fig. 168 is 300
mm in diameter and is actuated by a
mechanism that exerts the same
force F on each shoe. The shoes are
identical and have a face width
of 32 mm. The lining is a molded
asbestos having a coefficient of
friction of 0.32 and a pressure
limitation of 1000 kPa. Estimate the
maximum
a) Actuating force F
b) Braking capacity
c) Hinge-pin reactions.

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ME-305 Mechanical Engineering Design II

16-3 External Contracting Rim

Clutches and Brakes
The moments of the forces are the
same as in case of internal
contracting brakes and clutches
The only change is the change in
direction of the normal force dN.
Thus
(For c.w. rotation)
(For c.c.w. rotation)

MN and Mf are the same as

calculated in section 16-2.

Reactions forces on the pin are;

A and B are the same as calculated in section 16-2.

c

ME-305 Mechanical Engineering Design II

16-3 External Contracting Rim

Clutches and Brakes

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The block-type hand brake shown in the figure has a face

width of 30 mm and a mean coefficient of friction of 0.25. For
an estimated actuating force of 400 N, find the maximum
pressure on the shoe and find the braking torque.

Linear Sliding Wear

Wear is denoted by w (in mm)
Consider a block moving against a plate with pressure p,
on area A and fs
We can write;

Volume removed due to wear = work done by force by

displacing the block (1)

Volume removed =
Work done by force =
Block displacement =
(1) becomes

(mm3)
(N)
(mm)

(mm)
Where K is the proportionality constant depends on
Material and units are

.
. .

K is determined experimentally by the manufacturers.

ME-305 Mechanical Engineering Design II

Symmetrically located long shoe

brake and clutch

ME-305 Mechanical Engineering Design II

Problem 16-5

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For constant wear in the shoe, we can write;

Force is applied along x-axis, so maximum wear wo is
along x-axis. We can write;

and
Since all surface see same w0 and speed for same time
is constant. We write;
so
constant
pa is maximum pressure.
We know that;
Put for p, we have
.

ME-305 Mechanical Engineering Design II

Symmetrically located long shoe

brake and clutch

ME-305 Mechanical Engineering Design II

Symmetrically located long shoe

brake and clutch

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We need to Fix pivot point such that to get Mf = 0. Zero

Mf ensure that;
a) Ry creates a uniform wear
b) The pressure distribution is cosinusoidal
We can write (see Fig);
2

Put for dN to get;

2
2
If a is not correct, Mf dislocates and non-uniform wear,
cause the shoe life low.
The reactions are;
2
2
2

ME-305 Mechanical Engineering Design II

Symmetrically located long shoe

brake and clutch

Because of symmetry
and
The torque capacity is

ME-305 Mechanical Engineering Design II

Symmetrically located long shoe

brake and clutch

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ME-305 Mechanical Engineering Design II

16-6 Disk Brakes

No fundamental difference between disk
clutch and disk brake
Analysis procedure is the same
In drum brake, a small change in cof due
to temperature or moisture causes a large
difference in pedal force
30% reduction is found in cof due to temp.
and moist.
No self-energization in disk brake and has
minimum changes to cof.
Disk brakes are designed based on;

Uniform pressure theory

Uniform wear theory

A brake or friction clutch should have the following lining

material characteristics to a degree that is dependent on
the severity of service
High and reproducible coefficient of friction
Imperviousness to environmental conditions, such
as moisture
The ability to withstand high temperatures, together
with good thermal conductivity, as well as high
specific heat capacity
Good resiliency
High resistance to wear
Compatible with environment
Flexibility

ME-305 Mechanical Engineering Design II

16-10 Friction Materials

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ME-305 Mechanical Engineering Design II

16-10 Friction Materials

ME-305 Mechanical Engineering Design II

16-10 Friction Materials

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ME-305 Mechanical Engineering Design II

16-10 Friction Materials

Manufacture of friction material is highly
specialized process
Consult the manufacturers for catalogue,
handbook or specs
Select the material based on your design
requirements as well as the standard sizes
available

ME-305 Mechanical Engineering Design II

16-10 Friction Materials

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ME-305 Mechanical Engineering Design II

Problems from Chapter 16

Problem No. 1
Problem No. 2
Problem No. 3
Problem No. 4
Problem No. 5
Problem No. 7
Problem No. 8
Problem No. 10