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Representation
Brakes or Clutch
angular velocity
1 2 I inertia
Flywheel
I2
I1
Performance Analysis
Step 1.
Shoes is short assume that pressure is uniform
Step 2.
From step 1 p pa , pa maximum pressure
Step 3.
Since the pressure is uniformly distributed, the normal
forces is given by
N pa A pa (w 1 w 2 ) (a)
Taking the moment about point A, gives
M A Fb Nb fNa 0 (b)
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
Fx 0 R x fp a (w 1 w 2 )
(d)
Fy 0 R y p a (w 1 w 2 ) F
Step 1
Make the assumption that the pressure at any point is
proportional to the vertical distance from the hinge
pin. This vertical distance is proportional to sin.
Step 2
From the step 1, the relation between the pressure is
Step 3
At the angle from the hinge pin, there acts a differential
normal force dN whose magnitude is.
dN pbr d (b)
Where b is the face width of the friction material.
Substituting the value of the pressure, eq. (1), we find
pa br sin d
dN (c)
sin a
The normal force, dN and other forces act on the friction
material can be decomposed into horizontal and vertical
component, as shown on the figure.
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
Step 3 (continued)
The actuating force F can be found by using the condition
that the summation of the moments about the hinge pin is
zero. 2
fp a br
M f fdN r a cos sin r a cos d (2)
sin a 1
2
p a bra
M N dN a sin sin 2
d (3)
sin a 1
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
MN Mf (5)
Step 3 (continued)
The hinge pin reactions are found by taking a summation
of the horizontal and vertical forces, thus we have
R x dN cos fdN sin F x
p a br (d)
A fB F x
sin a
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 Mf
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:
Step 3 (continued)
Force Analysis
The notation for external
contracting shoes is shown
in Figure 7.
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 7
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
2
fp a br
M f fdN r a cos sin r a cos d (2)
sin a 1
2
p a bra
M N dN a sin sin 2
d (3)
sin a 1
MN Mf
F (11)
c
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
where
2 2
A sin cos d sin B sin d 2 sin 2
2
2 2 2
1 1
2 1 4 1
1 1
r
x
wear
Figure 8
p pa cos (a)
and p is maximum at 0o
• The normal force, from Fig 8.a we find that
dN pbr d (b)
or
dN p a br cos d (c)
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
0
• From which we obtain
Rework this result at
4r sin2
a (15) home by your own way!
22 sin 22
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
T af N (18)
Element d, in
equilibrium under
the action of the
forces, so summing
the forces in
P1 P2 Why? vertical direction,
we have
Figure 9 Note:
for small angles,
(P dP ) sin d
2
P sin d
2
dN 0 (a)
d d
or *) sin
2 2
dN Pd (b) *)dP d 0
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
and
P1
ef (19)
P2
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
Figure 10 Figure 11
Single-plate disk clutch, Multiple-plate disk clutch,
application: car application: motor cycle
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
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 Figure 12
pressure by pa, we can d d
then write pr pa or p pa
2 2r
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
Ff
T D d (25)
4
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
Uniform Pressure
When uniform pressure can be assumed over the area of
the disk, the actuating force F is simply the product of
the pressure and the area pa 2
F 2
4
D d (26)
As before, the torque is found by integrating the product
of the frictional force and the radius:
fpa 3
D d 3 (27)
D/2
T 2fpa r dr
2
d 2
24
Ff D 3 d 3
T (28)
3 D2 d 2
Note:
All equations are for single pair of mating surface. This value must be
therefore be multiplied by the number of pairs of surfaces in contact:
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
Difference characteristic of
uniform pressure and uniform wear
Figure 13
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
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.
Uniform Wear
The pressure relation is the
same as for the axial clutch
d Figure 15
p pa (a)
2r
Note that Eq. (24) is a special case of Eq. (30), with = 90o.
Using Eq. (29), the torque can also be written
Ff
T D d (31)
4 sin
Uniform Pressure
Using p = pa, the actuating force and torque are found to be
D 2
2r dr p a 2
F p a dA sin p a sin
D d 2 (32)
d 2 sin 4
D 2
2r dr fp a
T rfpa dA
a sin 12 sin
rfp D 3
d 3
(33)
d 2
Ff
D3 d 3
T (34)
3 sin D 2 d 2
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
Energy Conservations
• In the case of braking action, the kinetic energy must be
absorbed by the brake.
• This energy appears in the brake in the form of heat.
• 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 the
temperature-rise problem.
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
(I 1 I 2 )
u T T (1 2 ) T
t (e)
I 1I 2
This equation shows that the energy-dissipation rate is
greatest at the start of clutching, when t = 0.
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
Notes:
This is energy is absorbed by clutch or brake.
In SI unit, the inertias are expressed in kg-m, the
angular velocities are in rad/s, and the energy
dissipated is expressed in joules.
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
Temperature Rise
The temperature rise of the clutch or brake assembly can
be approximated by the classic expression.
T temperatur e rise, o C
E
T (38) C specific heat;
C m (use 500 J/kg for steel or cast iron)
m mass of clutch or brake parts, kg
Figure 17
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
Friction Material
A brake or clutch friction material should have the
following characteristics to a degree which is dependent
upon the severity of the service:
1. A High and uniform coefficient of friction
2. Imperviousness to environmental conditions, such as
moisture
3. The ability to withstand high temperature, together
with good heat conductivity
4. Good resiliency
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.
Flywheel
A flywheel is used to smooth out variations in the speed of a
shaft caused by torque fluctuations.
Piston compressors, 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
smooth loads such as an electrical generator driven by a steam
turbine, have no need for a flywheel.
If the source of driving torque or the load torque have a
fluctuating nature, then a flywheel is usually called for.
A flywheel is an energy storage device. It absorbs and stores
kinetic energy when speeded up and returns energy to the
system when needed by slowing its rotational speed.
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
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 and non-linear differential
equation. We can dispense with this here by assuming a rigid
shaft, giving i = = o . Thus, Eq. (a) becomes
I T i ( , i ) T o ( , 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.)
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
Figure 20
The work input to the flywheel is the area of the rectangle
between 1 and 2 , or.
U i Ti (2 1 ) (c)
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
E E 2 E 1 12 I 22 12 (40)
Note:
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.
Read and rework example 16-2.
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
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. 21. 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 Figure 21
peak crankshaft torque?
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
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 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 20 kJ. This is equivalent to 20 kW or 62.8 kW
or 84.2 hp.
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
Example 2.
For the punch press in
example 1 determine the
motor power capacity
required if use is made 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. 22, which
is 2 kN·m or 6283 Joules.
Figure 22
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
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. 23.
Figure 23
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.
Assumption/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. 23.
5. The inertia contributed by the hub and arms is negligible.
6. Friction losses are negligible.
Solution:
1. Fig. 22 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 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
(*)
MS3116 – Element Mesin II ‹#›
Analysis of Break & Clutch
max 1
3
1200 rpm 40
rad
13.33
rad
3 s s
30 rad rad
min 13 900 rpm 10
3 s s
Substituti on these values to the Eq. (*) gives
5236 12 I 13.33 2 10 2 I 13.80 kg m2
Comment:
If the inertia contributed by the hub and arms is included in the analysis,
we would find that a smaller d is required.
MS3116 – Element Mesin II ‹#›