Brake & Clutch Analysis PDF

Analysis of Break & Clutch
MS3111 – Element Mesin II 1
Representation
Brakes or Clutch
  angular velocity
1 2 I  inertia
I2 Flywheel
I1
T  torque
T i ,i T o ,o
  angular displaceme nt
I ,
1
Performance Analysis
 The actuating force (gaya aktivasi)
 The torque transmitted (torsi diteruskan)
 The energy loss (rugi-rugi)
 The temperature rise (kenaikan temperatur)
Various Types of Devices

 Rim types with internal expanding shoes
 Rim type with external contracting shoes
 Band types
 Disk or axial types
 Cone types
 Miscellaneous types
2
General procedures of analysis

steps.
1. Estimate or determine the
distribution of pressure on
the frictional surfaces.
2. Find a relation between the
maximum pressure and the
pressure at any point.
3. Apply the conditions of
static equilibrium to find
the actuating force, the
torque, and the support
reactions.
Figure 16-2
• A normal pressure distribution p(u) is shown under the friction pad

as a function of position u, taken from the right edge of the pad.
• Distribution of shearing frictional traction is on the surface, of
intensity f p(u), in the direction of the motion of the floor relative to
the pad, where f is the coefficient of friction.
• The net force in the y direction and moment about C from the pressure
are respectively,
• We sum the forces in the x-direction to obtain
3
• Assuming f constant, solving for Rx gives
where − or + is for rightward or leftward relative motion of the

floor, respectively.
• Summing the forces in the y direction gives
from which
for either direction.

f p av w1 w 2 f p av w1 w 2
u u
p av w1 w 2 p av w1 w 2
f p av w1 w 2 f p av w1 w 2
Rightward relative motion Leftward relative motion

of the floor of the floor
4
• Summing moments about the pin located at A we have
A brake shoe is self-energizing if its moment sense helps set the brake
and is self-deenergizing if the moment resists setting the brake.
The above equation gives
• Can and when F be equal to or less than zero?

Only during rightward motion of the floor, the expression in
brackets in Eq. (e) is equal to or less than zero.
• We set the brackets to zero or less:
from which
Where u is the distance of the center of pressure from the right edge
of the pad.
5
Some remarks:
 The conclusion that a self-acting or self-locking
phenomenon is present and is independent of our
knowledge of the normal pressure distribution p(u).
 Our ability to find the critical value of the
coefficient of friction fcr is dependent on our
knowledge of p(u), from which we derive.
Example 1
6
7
8
 If the doorstop rotates  ccw, the right and

left edges of the pad will deform down y1
and y2, respectively (Fig. 16–2b).
Figure 16-2 (b)  From similar triangles, y1/(r1  ) = c/r1 and
y2/(r2 ) = (c + w1)/r2. Thus, y1 = c  and
y2 = (c + w1)  .
 This means that y is directly proportional
to the horizontal distance from the pivot
point A; that is, y = C1v, where C1 is a
constant (see Fig. 16–2b).
 Assuming the pressure is directly
proportional to deformation, then p(v) = C2v,
where C2 is a constant. In terms of u, the
pressure is p(u) = C2(c + u) = C2(1.6 + u).
9
10
Internal Expanding Rim Clutches & Brakes
(a) Clutch (b) Brake

Figure 3 Expanding rim type
 Internal-shoe rim expanding type consist of 3 elements:

• the mating frictional surface,
• the means of transmitting the torque to and from the
surfaces,
• the actuating mechanism.
 Depending upon the operating mechanism, such clutches are
further classified as:
expanding-ring, centrifugal, magnetic, hydraulic, and pneumatic.
 The expanding-ring clutch is often used:
in textile machinery, excavators, and machine tools.
 In braking systems, the internal-shoe or drum brake is used mostly
for automotive applications.
11
Force Analysis  Let us consider the unit pressure p acting

upon an element of area of the frictional
p material located at an angle  from the
hinge A.
 We designate the maximum pressure by
pa located at the angle a from the hinge
pin A.
 The mechanical arrangement permits no
pressure to be applied at the heel (point
A)  the pressure at this point is
assumed to be zero.
 In some designs the hinge pin is made
Figure 4 movable to provide additional heel
pressure.
In this case, as long shoe, the uniform distribution of pressure is not valid anymore !
The following assumption are implied by the following analysis:

1. The pressure at any point on the shoe is assumed to be proportional
to distance from the hinge pin, being zero at the heel.
2. The effect of centrifugal force has been neglected. In the case of
brakes, the shoes are not rotating, and no centrifugal force exists.
In clutch design, the effect of centrifugal force must be considered in
writing the equations of static equilibrium.
3. The shoe is assumed to be rigid. Since this cannot be true, some
deflection will occur, depending upon the load, pressure, and stiffness
of the shoe. The resulting pressure distribution may be different from
that which has been assumed.
4. The entire analysis has been based upon a constant coefficient of
friction (does not vary with pressure). Actually, the coefficient may
vary with a number of conditions including temperature, wear, and
environment.
12
Step 1
Make the assumption that the pressure at any point is proportional to the
vertical distance from the hinge pin. p
This vertical distance is proportional to sin  p  sin    const
sin 
Step 2
To find the pressure distribution on the
periphery of the internal shoe, consider
point B on the shoe (Fig. 5).
 As in Ex. 16–1, if the shoe deforms by an
infinitesimal rotation  about the pivot
point A, deformation perpendicular to AB
is h .
 From triangle AOB, h = 2 r sin(θ/2), so
Figure 5
 The deformation perpendicular to the rim is h  cos(θ/2),

which is
Thus, the deformation, and consequently the pressure, is

proportional to sin θ.
 In terms of the pressure at B and where the pressure is a

maximum, this means
(a) OR (1)
This pressure distribution has interesting and useful characteristics:

13
 The useful characteristics of the previous pressure distribution are:

 The pressure distribution is sinusoidal, see Fig. 6.
 If the shoe is short, Fig. 6a, the largest pressure on the shoe is pa
occurring at the end of the shoe, θ2.
 If the shoe is long, Fig. 6b, the largest pressure on the shoe is pa
occurring at θa = 90o.
Figure 6
 In choosing friction material, the designer should think in terms of pa

and not about the amplitude of the sinusoidal distribution that addresses
locations off the shoe.
Step 3
 At the angle  from the hinge pin,
there acts a differential normal
force dN whose magnitude is.
(b)
where b is the face width of the
friction material.
 Substituting the value of the
pressure, eq. (1), we find
(c)
Drum’s
rotation Figure 7
14
Step 3 (continued)
 The normal force, dN and other forces act on the friction material can
be decomposed into horizontal and vertical component, as shown on
Fig. 7.
 The actuating force F can be found by using the condition that the
summation of the moments about the hinge pin is zero.

fp br 2
Mf  fdN r  a cos    a  sin  r  a cos  d (2)
sin  a 1

pa bra 2 2
M N   dN a sin    (3)
sin  a 1
sin  d
 The actuating force F must balance these two moments:

MN M f
F (4)
MS3111 – Element Mesin II
c 29
Step 3 (continued)
 If we make MN = Mf , self-locking is obtained, and no actuating force is
required.
 To obtain self-energizing condition, the dimension a in figure must be
such that
M M N
(5)
f
 The torque T applied to the drum by the brake shoe is the sum of the
frictional forces fdN times the radius of the drum:
fpa br 2 cos 1  cos  2 


fpa br 2 2
T 
sin  a 1
fr dN  sin  d  (6)
sin  a
Braking capacity
15
Step 3 (continued)
 The hinge pin reactions are found by taking a summation of the
horizontal and vertical forces, thus we have
Rx   dN cos    fdN sin   Fx
pa br (d)
  A  fB   Fx
sin  a
R y   dN sin    fdN cos   Fy

pa br (e)
 B  fA  Fy
sin  a
where
2 2
A   sin  cos  d   1
2 sin 
2
 2
1
B   sin 2  d  2  14 sin 2   2

1
1 1
Step 3 (continued)
 The direction of the frictional forces is reversed if the
rotation is reversed. Thus, for counterclockwise rotation of
drum, the actuating force become
MN  M f
F (7)
c
 Since both moments have the same sense, the self-energizing
effect is lost and also self-locking.
 Also, for counterclockwise rotation the signs of frictional
terms in the equilibrium for the pin reactions change, and
equation (d) and (e) become:
16
Step 3 (continued)
Rx   dN cos    fdN sin   Fx



pa br
 A  fB   Fx (f) 
sin  a  For
 counterclockwise
R y   dN sin    fdN cos   Fy  rotation
pa br 
 B  fA  Fy (g)

sin  a
Example 2
The brake shown in Fig. 8 has 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. Figure 8
17
Solution Example 2
18
19
The reactions at the hinge pin of the

left-hand shoe are found, using eq. (f)
and (g) for a pressure of 443 kPa.
They are found to be Rx = 0.678 kN
and Ry = 0.538 kN.
The resultant is
The reactions for both hinge pins,

together with their directions, are
shown in Fig. 9.
Figure 9
20
External Contracting Rim Clutches & Brakes

The patented clutch-brake of figure
has external contracting friction
elements, but the actuating
mechanism is pneumatic.
The mechanism can be classified as:
1. Solenoids
2. Levers, linkages, or toggle
devices
3. Linkages with spring loading
4. Hydraulics and pneumatic
Figure 10 devices
Force Analysis
The notation for external
contracting shoes is shown
in Figure 11.
The moments of friction
and normal forces about the
hinge pin are the same as
for the internal expanding
shoes.
Equations (2) and (3) apply
and repeated here for
convenience:
Figure 11
21

fpa br 2
Mf    sin  r  a cos  d
sin  a 1
fdN r  a cos   (2)

pa bra 2 2
M N   dN a sin   
sin  a 1
sin d (3)
Both equation give positive value for clockwise moments

when used for external contracting shoes.
The actuating force must be large enough to balance both
moments:
MN  M f
F (11)
c
The horizontal and vertical reactions at the hinge pin are:
Rx   dN cos    fdN sin   Fx (12a)

pa br
  A  fB   Fx
sin  a
R y   fdN cos    dN sin   Fy

(12b)
p br
 a  fA  B   Fy
sin  a
where
2 2
A   sin  cos  d   1
2 sin 2
 2
1
B   sin 2  d  2  14 sin 2   2

1
1 1
22
If the rotation is counterclockwise, the sign of the frictional term in

each equation is reversed. Thus equation for actuating force becomes
MN M f
F (13)
c
And self-energization exist for counterclockwise rotation.
The horizontal and vertical reaction are found to be
pa br
Rx   A  fB   Fx (14a)
sin  a
pa br
Ry   fA  B   Fy (14b)
sin  a
• When external contracting designs are used as clutches, the effect of

centrifugal force is to decrease the normal force. Thus, as the speed
increases, a larger value of the actuating force F is required.
• A special case arise when the pivot is symmetrically located and
also placed so that the moment of the friction forces about the pivot is
zero.The geometry of such a brake will be similar to that of Fig. 12 (a).
• To get a pressure-distribution relation, we assume that the lining wear
is such to retain its cylindrical shape, much as a milling machine
cutter feeding in the x direction would do to the shoe held in a vise,
see Fig. 12 (b).
• This means the abscissa component of wear is w0 for all positions θ.
If wear in the radial direction is expressed as w(θ), then.
w( )  w0 cos 
23
f dN
dN Figure 12
Figure 10
• The radial wear w(θ) can be expressed as

w( )  K P V t
where K is a material constant, P is pressure, V is rim velocity,
and t is time.
• Denoting P as p(θ) above and solving for p(θ) gives
• Since all elemental surface areas of the friction material see the same
rubbing speed for the same duration, w0/(KVt) is a constant and
where pa is the maximum value of p(θ).
24
• Proceeding to the force analysis, we observe from Fig. 12 (a) that
or
• The distance a to the pivot is chosen by finding where the moment

of the frictional forces Mf is zero.
• First, this ensures that reaction Ry is at the correct location to establish
symmetrical wear.
Second, a cosinusoidal pressure distribution is sustained, preserving
our predictive ability.
• Symmetry means θ1 = θ2, so
• Substituting value of dN, we obtain
from which
(*)
• The distance a depends on the pressure distribution. Mislocating the
pivot makes Mf zero about a different location, so the brake lining
adjusts its local contact pressure, through wear, to compensate.
• With the pivot located according equation (*), the moment about the
pin is zero, and the horizontal and vertical reactions are
25
where, because of symmetry,

• Also,
where
Also because of symmetry.

• Note, too, that Rx = −N and Ry = −f N, as might be expected for the
particular choice of the dimension a.
• Therefore the torque capacity is
Band-Type Clutches and Brakes

Application, mostly:
• Power excavators
• Hoisting machinery
• Others
Broderson IC-80-1D Carry Deck

• Engine: Continental TM27, 4 cyl., 165 C.I.D.,
64 hp at governed speed.
• Transmission: Borg Warner, 72T/T18,
Reversing Gearbox and Manual Shift Three
Speed Gearbox.
• Brakes: Service - 4-wheel drum type

brakes, Parking - Band Type Mounted
on Transmission
26
Figure 13
P1  P2 Why?
Note:
Forces in vertical direction gives:
for small angles,
( P  dP ) sin d2  P sin d2  dN  0 (a) d d
*) sin 
2 2
or dN  Pd (b) *)dP  d  0
Forces in horizontal direction gives

( P  dP) cos d2  P cos d2  f dN  0 (c)
or
dP  f dN  0 (d)
Substituting the value of dN from Eq. (b) in (d) and
integrating gives
P1 
dP P1
 P 0
P2
 f d  ln
P2
 f
and
P1
 e f (15)
P2
27
The torque may be obtained from the equation

T  P1  P2  D2 (16)
The normal force dN acting on element is
dN  pb r d (e)
Substitution of dN from Eq. (b) gives
P d  pb r d
Therefore The pressure is therefore
P 2P
p  (17) proportional to the tension
br b D in the band.
The maximum pressure will 2 P1

pa  (18)
occur at the toe with the value bD
Frictional-Contact Axial Clutches

• Mating frictional members are moved
in a direction parallel to shaft.
• Most application: automotive
28
Figure 14 Figure 15
Single-plate clutch, A, driver; B, Multiple-plate disk clutch,
driven plate (keyed to driven application: motor cycle
shaft); C, actuator
 Advantages of the disk clutch:

 Free from centrifugal effects
 Large frictional area which can be installed in
small space
 More effective heat-dissipation surfaces
 Favorable pressure distribution
 Two methods for the analysis:

 Uniform wear
 Uniform pressure
29
 Uniform wear
After initial wear has taken
place and the disks have worn
down to the point where
uniform wear becomes
possible, the greatest pressure
must occur at r = d/2 in order
for wear to be uniform.
Denoting the maximum
pressure by pa, we can then Figure 16
write.
(see the explanation in d d
pr  pa or p  pa
Shigley, page 847) 2 2r
Referring to Fig. 16, we have an element of area of radius r and

thickness dr. The area of this element is 2r dr , so that the
normal force acting upon this element is dF = 2pr dr . Thus, the
total normal force become
D/2 D/2
pa d (19)
F  2pr dr  p d  dr 
a D  d 
d 2 d 2
2
The torque is found by integrating the product of the frictional

force and the radius
D/2 D/2
fpa d
T  2fpr dr  fpa d
2
 rdr  8
D 2
d2  (20)
d 2 d 2
Ff
T D  d  (21)
4
30
 Uniform Pressure
When uniform pressure can be assumed over the area of the
disk, the actuating force F is simply the product of the
pa 2
pressure and the area 2
F
4
D d  (22)
As before, the torque is found by integrating the product of the
frictional force and the radius:
D/2
fpa
T  2fpa  r dr 
2
24
D 3
d3  (23)
d 2
T

Ff D 3  d 3  (24)
3 D2  d 2
Note:
Equations (21) and (24) are for single pair of mating surface.
This value must be multiplied by the number of pairs of surfaces in contact.
Difference characteristic
of uniform pressure and
uniform wear
T
UW   14 1   Dd 
fFD
UP 
T 
 13 
1   D 
d 3
2
fFD 1   Dd  
Figure 17
31
Disk Brakes
• There is no fundamental
difference between a disk clutch
and a disk brake.
• The analysis of preceding section
applies to disk brakes too.
• Disk brake has no self-
energization, and hence is not so
susceptible to changes in the
coefficient of friction.
• Fig. 18 shows a floating caliper

disk brake.
• The caliper support a single
floating piston actuated by
hydraulic pressure.
• The action is like a screw clamp,
with the piston replacing the
function of the screw.
• The floating action compensates
for wear and ensures a fairly
constant pressure over the area
of the friction pads.
Figure 18
32
Annular-pad brake contact area.

Fig. 19 is the geometry of an
annular-pad brake contact area.
The governing axial wear equation is
(see Eq. 12-27, p. 663 - Shigley)
w  f1 f 2 KPVt (25)
The coordinate r locates the line of

action of force F that intersects the y
Figure 19 axis.
Of interest also is the effective radius re, which is the radius of an
equivalent shoe of infinitesimal radial thickness.
If p is the local contact pressure, the actuating force F and the

friction torque T are given by
(26)
(27)
33
The equivalent radius re can be found from f F re = T , or
(28)
The locating coordinate r of the activating force is found by

taking moments about the x axis:
(29)
Uniform Wear
Using that pressure distribution p = pari /r, Eqs. (26) to (29)
become
(30)
(31)
(32)
(33)
34
Uniform Pressure
In this situation, approximated by a new brake, p = pa, Eqs. (26)
to (29) become
(34)
(35)
(36)
(37)
Example 3
Solution Example 3
(a) From Eq. (31), with T = 13 000/2 = 6500 lbf · in for each pad,
Answer
35
(b) From Eq. (30),

Answer
(c) From Eqs. (32) and (33),
Answer
Answer
(c) Each cylinder supplies the actuating force, 3748 lbf.
Answer
Circular (Button) Pad Caliper Brake

Figure 20 displays the circular pad geometry.
Numerical integration is necessary to analyze this
brake since the boundaries are difficult to handle
in closed form. Table 1 gives the parameters for
this brake as determined by Fazekas.
Table 1 Parameters for a Circular-Pad Caliper Brake
Effective radius, re   e
Figure 20
36
The effective radius is given by
re   e (38)
The actuating force is given by
F   R 2 pav (39)
and the torque is given by
T  fFre (40)
Example 4
Solution Example 4
From Table 1, by interpolation, δ = 0.963 and pmax/pav = 1.290.

It follows that the effective radius e is found from Eq. (38):
37
The actuating force F is found from Eq. (39) to be
Answer
Answer
Cone Clutch and Brakes

• Consist of a cup and a cone.
• Cone angle, the diameter and face
width of the cone are the important
geometric design parameters.
• If the cone angle is too small, say,
less than about 8o, then the force
required to disengage the clutch may
be quite large.
• Wedging effect lessens rapidly when
larger cone angles are used.
• A good compromise can usually be
found between 10o – 15o.
38
Actuating force and torque

transmitted can be found
using Fig. 21.
Uniform Wear
The pressure relation is the
same as for the axial clutch
d
p  pa (a)
2r Figure 21
The element area dA of radius r and width dr sin is

dA  (2r dr ) sin  (b)
As shown in Fig. 21, the operating force will be the integral of the
axial component of the differential force pdA. Thus
D2
 d  2r dr 
F   pdA sin     p  (sin  )
2r  sin  
a
d 2
D2
pa d (41)
F  pa d  dr  D  d 
d 2
2
which is the same result as in Eq. (19).
The differential friction force is f p dA, and the torque is
D 2
 d  2r dr 
T   rfp dA   (rf ) p   Note that Eq. (20) is
2 r  sin  
a
d 2
a special case of Eq.
D 2
fp a fp a d
 r dr  8 sin  D  (42) (42), with  = 90o.
T 2
d2
sin  d 2
39
Using Eq. (41), the torque can also be written

Ff Note that Eq. (21) is also a
T D  d  (43) special case of Eq. (43),
4 sin 
with  = 90o.
Uniform Pressure
Using p = pa, the actuating force and torque are found to be
D 2
 2r dr  p
F   pa dA sin    pa   sin   a D  d
2 2
  (44)
d 2  sin   4
D2
 2r dr  fp
T   rfpa dA   rfp  sin    12 sin  D d3 
3
(45)
a
a
d 2
Ff D 3  d 3
T (46)
3 sin  D 2  d 2
As in the case of the axial clutch, we can write Eq. (43) dimensionlessly as
T sin  1  Dd
 ( c)
f FD 4
And write Eq. (46) as
T sin  1  1   Dd  
3
  (d )
f F D 3  1   Dd 2 
This time there are six (T, α, f, F, D, and d) parameters and four pi () terms:
T d
1  2  f  3  sin  4 
FD D
As in Fig. 17, we plot T sin α/( f FD) as ordinate and d/D as abscissa. The
plots and conclusions are the same  Students are recommended to do
the plot.
40
Energy Considerations
• In the case of braking action, the kinetic energy must be
absorbed by the brake system.
• For the clutching action, slipping must occur in the clutch
until the driven parts have the same speed as the driver.
• Kinetic energy is absorbed during slippage of either a clutch
or brake, and this energy appears as heat.
• The capacity of a clutch or a brake is limited by two factors:
characteristic of material and ability of clutch/brake to
dissipate heat.
• If the heat generated faster than it is dissipated, we have the
temperature-rise problem.
To study what happens during a simple clutching/braking operation,

let see the Fig. 22 .
Brakes or Clutch  I1 and I2 have initial

angular velocity of 1
and 2
1 2 (generaly1 ≠2).
 During the clutch
I2 operation, both angular
I1 Figure 22 velocity change and
eventually become
Two basic assumptions: equal.
 The two shafts are rigid
 The torque is constant.
41
 Equation of motion for inertia 1 and 2 can be written:

I11  T (a) where  is angular acceleration
I   T
2 2 (b) and T is clutch torque.
 The instantaneous angular velocities for both inertia can be

determined as follows
T (c) T
1  t  1 2  t  2 (d)
I1 I2
 The difference in velocities (relative velocity), is
2 
      T t    T t  
1 I1 1   I2 2 
 I1  I 2 
  1  2   T   t (47)
I I
 1 2 
The clutching operation is completed at the instant when both

angular velocity become equal. Let the time required for entire
operation be t1. Then the Eq. (47) gives the time as
I I (   2 )
1  2    0  t1  1 2 1 (48)
T ( I1  I 2 )
Using Eq. (47), the rate of energy-dissipation during the
clucthing operation is
  I  I2  
u  T   T  ( 1   2 )  T  1  t  (e)
 I I
 1 2  
This equation shows that the energy-dissipation rate is greatest
(maximum) at the start of clutching, when t = 0.
42
 The total energy dissipated during the clutching operation or

braking cycle is obtained by integrating Eq. (e) from t = 0 to t
= t1. The result is found to be
t1

t1
 (I  I2 )  
E   udt
0
 T   ( 1   2 )  T  1
0   I 1 I 2
 t  dt
 
1  I1 I 2 
E    ( 1   2 ) 2 (49)
2  I 1  I 2 
Notes:
This is the energy that must be absorbed by clutch or brake.
 In USCS units, if the inertias are expressed in (lbf · in ·

s2), then the energy absorbed is in (in · lbf).
Using this units, the heat generated in Btu is.
E
H  (50)
9336
 In SI unit,
 inertias are expressed in [kg-m2]
 angular velocities are in [rad/s]
 energy dissipated is expressed in [Joules].
43
Temperature Rise
 The temperature rise of the clutch or brake assembly can be
approximated by the classic expression.
E
T  (51)
C p W
where
T  temperature rise, o F
C p  specific heat capacity, [Btu/(lbm  o F]; use 0.12 for steel or cast iron
W  mass of clutch or brake parts, [lbm]
 A similar equation can be written for SI units. It is

E
T  (52)
Cp m
where
T  temperature rise, o C
C p  specific heat capacity, [J/kg  o C]; use 500 for steel or cast iron
m  mass of clutch or brake parts, [kg]
Notes:
 The temperature rise equations above can be used to explain what
happens when a clutch or brake is operated.
 However, there are so many variables involved that it would be most
unlikely that such an analysis would even approximate experimental
results.
44
 If an object is at initial temperature T1 in an environment to

temperature T, Newton’s cooling model is expressed as
T  T  h A 
 exp   CR t (53)
T1  T   W C 
 p 
where
T  temperature at time t , o F
T1  initial temperature, o F
T  environmental temperature, o F
hCR  overall coefficient of heat - transfer, Btu/(in 2  s  o F)
A  lateral surface area, in 2 .
W  mass of the object, lbm
C p  specific heat capacity of the objecy, Btu/(lbm o F)
 Figure 23 shows an application of Eq. (53). The curve ABC is

the exponential decline of temperature given by Eq. (53).
 At time tB a second
application of the brake
occurs.
 The temperature quickly
rises to temperature T2, and
a new cooling curve is
started.
 For repetitive brake
applications, subsequent
temperature peaks T3,
T4,…, occur.
 Please read the reference
book for a more detail
Figure 23
explanation of the graph.
45
 When a disk brake has a rhythm such as discussed above, then the
rate of heat transfer is described by another Newtonian equation:
H loss  hCR A T  T    h r  f v h c  A T  T   (54)
where
H loss  rate of energy loss, Btu/s
hCR  overall coefficient of heat - transfer, Btu/(in 2  s  o F)
hr  radiation component of hCR , Btu/(in 2  s  o F), Fig. 24(a)
hc  convective component of hCR , Btu/(in 2  s  o F), Fig. 24(a)
f v  ventilation factor, Fig. 24(b)
T  disk temperature, o F
T  ambient temperature, o F)
Figure 24
46
 The energy E absorbed by the brake stopping an equivalent

rotary inertia I in terms of original and final angular velocities ωo
and ωf is given by Eq. (50) and Eq. (49) with I1 = I and I2 =0
1 I
E ( 02   2f ) in Btu (55)
2 9336
 The temperature rise T due to a single stop is

E
T  (56)
WC
Tmax has to be high enough to transfer E Btu energy in t1 seconds.
 For steady state, rearrange Eq. (53) as

T min  T 
 exp   t1  (57)
T max  T 
h CR A
where   ; with A = lateral area
W Cp (heat transfer area)
 Cross-multiply, add Tmax to both sides of Eq. (57) and letting Tmax
– Tmin = T, and rearrange, we obtain
T
T max  T   (58)
1  exp   t1 
47
Example 5
Solution Example 5
From Fig. 24- (b) with air speed of 25 ft/s we find fv = 4.8, and so we have
48
Answer
Answer
Friction Material
A brake or friction clutch should have the following lining material
characteristics to a degree that is dependent on the severity of service:
• A high and uniform coefficient of friction.
• Imperviousness to environmental conditions, such as moisture.
• The ability to withstand high temperatures, together with good
thermal conductivity and diffusivity, as well as high specific heat
capacity
• Good resiliency.
• High resistance to wear, scoring, and galling.
• Compatible with the environment
• Flexibility.
49
 Table 16–2 gives area of friction surface required for several braking
powers.
 Table 16–3 gives important characteristics of some friction materials
for brakes and clutches.
 The manufacture of friction materials is a highly specialized process,
and it is advisable to consult manufacturers’ catalogs and handbooks,
as well as manufacturers directly, in selecting friction materials for
specific applications.
 Selection involves a consideration of the many characteristics as
well as the standard sizes available.
 Table 16–4 lists properties of typical brake linings.
 Table 16–5 includes a wider variety of clutch friction materials,
together with some of their properties.
Table of several common friction material

Material Fabrication Field of Application
Woven-cotton As a fabric belt which impregnated with Mostly in heavy machinery; usually in
lining resin and polymerized rolls up to 50 ft length. Thickess frm 1/8 in
to 1 in; width up to 12 in.
Woven-asbestos Similar to cotton lining and may contain Widely used as a brake material in heavy
lining metal particles. Not as flexible as cottong machinery. Comes in smaller range of
lining. sizes.
Molded-asbestos Contain asbestos fiber and friction Principal use is in drum brakes.
lining modifiers; thermoset polymer is used, with
heat, to form a rigid/semi0rigid molding.
Molded-asbestos Similar to molded lining but have no Used both for clutches and brakes.
pads flexibility.
Sintered-metal pads Made of a mixture of copper and/or iron Pads are used in both brakes and clutches
particles with friction modifiers; molded for heavy-duty applications.
under high pressure and the heated to a
high temperature to fuse the material.
Cermet pads Similar to the sintered-metal pads and have Pads are used in both brakes and clutches.
a substantial ceramic content.
50
51
52
Miscellaneous Clutches and Coupling

 Square-jaw clutch as shown in Fig. 25 (a) in one form of positive-
contact clutch. These clutches have the following characteristics:
1. They do not slip
2. No heat is generated
3. They cannot be engaged at high speeds
4. Sometimes they cannot be engaged when both shafts are at rest
5. Engagement at any speed is accompanied by shock.
 The greatest differences among the various types of positive clutches
are connected with the design of the jaws (ractched-shaped, spriral-
shaped, gear-tooth-shaped).
 Although positive clutches are not used to the extent of the frictional-
contact types, they do have important applications where
synchronous operation is required.
Square-jaw Overload-release clutch

Figure 25
53
 Devices such as linear drives or motor-operated screwdrivers must

run to a definite limit and then come to a stop.
 An overload-release type of clutch required for theses application.
Fig. 25 (b) is a schematic drawing illustrating the principle of the
operation of such clutch.
 This clutches are usually spring-loaded so as to release at a
predetermined torque.
 The clicking sound which is heard when the overload point is
reached is considered to be a desible signal.
 Both fatigue and shock must be considered in obtaining the stress and
deflections of the various portions of postive clutches. In addition,
wear must generally be considered.
 An overrunning clutch or coupling

permits the driven member of a
machine to “freewheel” or
“overrun” because the driver is
stopped or because another source
of power increases the speed of the
driven mechanism.
 The driving action is obtained by wedging the rollers between the

sleeve and the cam flats.
 There are many varieties of overrunning clutches available, and
they are built in capacities up to hundreds HP.
 Since no slippage is involved, the only power loss is that due to
bearing friction and windage.
54
Plain shaft coupling Light duty toothed coupling
BOST-FLEX through-bore coupling Three-jaw coupling
55
Flywheel
 A flywheel is an inertial energy-storage device. It absorbs mechanical
energy by increasing its angular velocity and delivers energy by
decreasing its velocity.
 A flywheel is used to smooth out variations in the speed of a shaft
caused by torque fluctuations.
 Piston comp., punch presses, rock crusher, etc. all have time-varying
loads.
 The prime mover (ex.: internal combustion engine) introduce torque
oscillations to the transmission shaft.
 Other systems may have both smooth torque sources and loads such as an
electrical generator driven by a steam turbine  no need flywheel.
 If the source of driving torque or the load torque have a fluctuating
nature (see Fig. 16-28) then a flywheel is usually needed.
56
Figure 16–28
Relation between torque and crank
angle for a one- cylinder, four-stroke–
cycle internal combustion engine.
57
 The equation of motion for the Flywheel

flywheel represented in Fig. 23 is
Ti ,  i To ,  o
 M  Ti (i ,i )  To (o ,o )  I   0

or I ,
I   Ti (i , i )  To (o , o ) T  torque;   angular displacement
(a)
Figure 23
Note:
 Ti is considered positive and To negative.
 Values of Ti and To may depend on the angular displacement and/or their angular
velocities.
 In many case (ex. induction motor), its characteristic depends upon only the speed of
the motor. Generally, motor manufacturers publish the torque-speed characteristics of
their various motors.
 When the input and output torque functions are given, Eq. (a) can be
solved for the motion of the flywheel using well-known techniques for
solving linear or non-linear differential equation.
We can simplify this by assuming a rigid shaft, giving i =  = o .
Thus, Eq. (a) becomes
I   Ti ( , i )  To ( , o ) (b)
 When the two torque functions are known and the starting values of
the displacement  and velocity  are given, Eq. (b) can be solved.
 Here, we are not really interested in the instantaneous values of these
terms at all. Primary, we want to know the overall performance of
the flywheel (what should its moment of inertia?, how do we match
the power sources to the load?, what are the resulting performance?,
etc.)
58
 To gain insight into the problem, a hypothetical situation is diagrammed

in Fig. 24.
Energy is given to
and store by flywheel
T , 2 3
Ti 
1
Ui
4 Figure 24
3 4
1 2 Uo 
To
Energy released
1 cycle
back to system
 The work input to the flywheel is the area of the rectangle between 1
and 2 , or.
U i  Ti  ( 2  1 ) (c)
 The work output of the flywheel is the area of the rectangle between 3
and 4 , or.
U o  To  ( 4  3 ) (d)
 Three conditions possible (assume: no friction losses)

If U o  U i  4  1 ; load uses more energy than has been delivered to the flywheel
If U o  U i  4  1 ; the gains and the losses are equal
If U o  U i  4  1 ; load uses less energy than has been delivered to the flywheel
 These relation can also be written in terms of kinetic energy.

At  = 1 the flywheel has a velocity of 1 rad/s, and so its kinetic
energy is
E1  12 I 12 (e)
59
 At  = 2 the velocity is 2 rad/s, and so its kinetic energy is

E2  12 I 22 (e)
 Thus the change in kinetic energy is

E  E2  E1  12 I 22  12  (36)
 Notes:
 Many of the torque displacement functions encountered on
practical engineering situations are so complicated that they must
be integrated by approximate methods.
 One simplest integration routine is Simpson’s rule. This
approximation can be handled on any computer and is short
enough to use on the smallest programmable calculators.
Example 1.
The crankshaft of a punch press
rotates at 60 rpm, causing holes to
be punched in a steel part at the
rate of 60 punches per minute.
The crankshaft torque requirement
is shown in Fig. 25. The press is
driven (through suitable speed
reducers) by a 1200-rpm motor.
Neglecting any “flywheel effect”,
what motor power is required to
accommodate the peak crankshaft
torque?
Figure 25
60
Assumption:
1. Friction losses are negligible
2. No energy is stored as rotational kinetic energy (no flywheel)
3. The motor delivers maximum torque continuously
Solution:
1. Neglecting friction losses  motor power = crankshaft power out,
and the 20 : 1 speed reduction (1200 rpm/60 rpm) is associated with
a 20 : 1 torque increase.
Hence, the motor torque required is 10 kN·m/20 = 500 N·m.
2. Motor delivers the torque continuously. The work capacity
corresponding to 1 revolution of the shaft is 2 x 500 N·m = 1000 J.
3. In 1 second, the motor shaft turns 20 revolutions (1200 rpm), the
work capacity is 20x1000 J = 20 kJ.
This is equivalent to 20 kW or 62.8 kW or 84.2 hp (a big motor ??)
Example 2.
For the punch press in
Example 1 determine the
motor power capacity required
if we use a flywheel.
The energy required for the
press is represented by the area
under the actual crank torque
versus the crank angle curve of
Fig. 26, which is  = 2
kN·m or 6283 Joules.
Figure 26
61
Assumption: Friction losses are negligible

Solution:
1. Fig. 26 shows that average torque requirement during the actual punch
stroke is 6 kN and that the punch stroke lasts for /3 rad. (The energy
involved is this area under the curve is 2 kN·m or 6283 J).
By using the flywheel that permits the motor to deliver a constant torque
over the entire 2 rad, we can reduce the torque requirement to 1 kN·m
 resulting a total energy of 2 kN.m (kJ)
This is shown in Fig. 26 as “uniform torque supplying equal energy”.
2. Since, at the same shaft speed, motor torque and motor power are
proportional, thus the 10:1 reduction (20  2) in motor torque
corresponds to a like reduction in power rating required.
Hence, the motor power required is 62.8 kW/10 = 6.28 kW or equal to 8.4
hp (a small motor).
Example 3.
Continuing with the previous
problem, we choose to design a
flywheel that rotates at 1/3 motor
speed and that limits motor speed
fluctuation to the range of 900
rpm to 1200 rpm. The flywheel is
to be made of steel and have the
geometric proportions as shown
in Fig. 27.
Figure 27
To simplify the calculation, assume that the inertia contributed by the hub
and arms is negligible. Determine the required flywheel polar moment of
inertia, I, and the diameter, d.
62
Assumption and decisions:

Assumptions:
1. Friction losses are negligible.
2. The inertia contributed by the hub and arms is negligible.
Decisions:
1. The flywheel rotates at 1/3 motor speed.
2. Motor speed fluctuation is limited to 900 to 1200 rpm.
3. The flywheel is made of steel.
4. Geometric proportions for the flywheel are shown in Fig. 27.
Solution:
1. Fig. 26 shows that during the
actual punch stroke, energy
provided by the motor is
represented by an approximate
rectangle 1 kN·m x /3 rad. Thus,
the motor provides 1000 N x /3 =
1047 J of the total of 6283 J
required.
The flywheel must provide the
remaining (6283 – 1047) = 5236 J.
2. The flywheel inertia must be such
that
5236  12 I max
2

 min
2
 (*)
Figure 26
63
40 rad rad

max  13 1200 rpm    13.33
3 s s
30 rad rad
min  13 900 rpm    10
3 s s
Substitution these values to the Eq. (*) gives

5236  12 I 13.33 2  10 2   I  13.80 kg  m 2
2. The moment of inertia for a hollow cylinder is
I 
32
d 4
o 
 d i4  L  
13.80  
32
d 4

 (0.8d ) 4 0.2d 7700
From wich we find d  688 mm
Comment:
If the inertia contributed by the hub and arms is included in the analysis, we
would find that a smaller d is required.
64

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Analysis of Break & Clutch

MS3111 – Element Mesin II 1

Analysis of Break & Clutch

 The actuating force (gaya aktivasi)

 The torque transmitted (torsi diteruskan)

 The energy loss (rugi-rugi)

 The temperature rise (kenaikan temperatur)

MS3111 – Element Mesin II 3

Analysis of Break & Clutch

Various Types of Devices

MS3111 – Element Mesin II 4

General procedures of analysis

Analysis of Break & Clutch

• A normal pressure distribution p(u) is shown under the friction pad

• We sum the forces in the x-direction to obtain

MS3111 – Element Mesin II 6

• Assuming f constant, solving for Rx gives

where − or + is for rightward or leftward relative motion of the

for either direction.

Analysis of Break & Clutch

Rightward relative motion Leftward relative motion

MS3111 – Element Mesin II 8

• Summing moments about the pin located at A we have

• Can and when F be equal to or less than zero?

MS3111 – Element Mesin II 9

Analysis of Break & Clutch

• We set the brackets to zero or less:

MS3111 – Element Mesin II 10

MS3111 – Element Mesin II 11

Analysis of Break & Clutch

MS3111 – Element Mesin II 12

MS3111 – Element Mesin II 13

Analysis of Break & Clutch

MS3111 – Element Mesin II 14

MS3111 – Element Mesin II 15

Analysis of Break & Clutch

MS3111 – Element Mesin II 16

 If the doorstop rotates  ccw, the right and

MS3111 – Element Mesin II 17

Analysis of Break & Clutch

MS3111 – Element Mesin II 18

MS3111 – Element Mesin II 19

Analysis of Break & Clutch

MS3111 – Element Mesin II 20

Internal Expanding Rim Clutches & Brakes

(a) Clutch (b) Brake

Analysis of Break & Clutch

 Internal-shoe rim expanding type consist of 3 elements:

MS3111 – Element Mesin II 22

Force Analysis  Let us consider the unit pressure p acting

Analysis of Break & Clutch

The following assumption are implied by the following analysis:

Analysis of Break & Clutch

 The deformation perpendicular to the rim is h  cos(θ/2),

Thus, the deformation, and consequently the pressure, is

 In terms of the pressure at B and where the pressure is a

This pressure distribution has interesting and useful characteristics:

 The useful characteristics of the previous pressure distribution are:

 In choosing friction material, the designer should think in terms of pa

Analysis of Break & Clutch

 The actuating force F must balance these two moments:

Analysis of Break & Clutch

fpa br 2 cos 1  cos  2 