Design of

Transmission
Systems

Dr. K. Kannan
Professor Mechanical Engineering
Anjalai Ammal Mahalingam Engineering College
Kovilvenni – 614 403

1
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.2

Topic Problems in clutch design

Design of plate clutches – Axial clutches – Cone

Recap clutches – Internal expanding rim clutches –
electromagnetic clutches

Learning Outcome
At the end of the lecture, the student will be able to
1. Solve problems in single plate, multi plate and cone clutch
under uniform pressure and wear conditions
2
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.2

Example 1: A single plate clutch effective on both sides is required

to transmit 25 kW at 3000 rpm. Determine the outer and inner
diameter of frictional surface if the coefficient of friction is 0.255,
ratio of diameters is 1.25 and the maximum pressure is not to
exceed 0.1 N/mm2. Also determine the axial thrust to be provided
by springs. Assume theory of uniform wear (AU-Nov. 2006, Nov.
2008)
Given data: P = 25 kW, N = 3000 rpm, μ = 0.255, D/d = R/r = 1.25,
p = 0.1 N/mm2, both sides are effective, uniform wear theory
Torque transmitted by the clutch
P  60 25000  60
M t
   79 . 62 Nm
2 N 2   3000

M t
 2  Q rm  79 . 62 Nm .....for both sides effective
3
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.2

Axial thrust to be provided by the springs for uniform wear theory

Q = 2 π pa r (R – r)
Q = 2 x 3.14 x 0.1 x 106 x r x (1.25 r – r) = 157000 x r2

Mean radius for uniform wear theory

R  r 1 . 25 r  r
rm    1 . 125 r
2 2

Inner diameter of the friction disc

M t
 2  Q rm  79 . 62 Nm .....for both sides effective

2  0 . 255  157000  r  1 . 125 r  79 . 62

2

79 . 62 4
  8 . 84  10
3
r
90078 . 75
r  0 . 096 m  d  0.192 m
4
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.2

Outer diameter of the friction disc

D = 1.25 d = 1.25 x 0.192 = 0.24 m

Axial thrust to be provided by the springs

Q = 157000 x r2 = 157000 x 0.0962 = 1446.9 N

Answer:
Inner diameter d = 19.2 cm
Outer diameter D = 24 cm
Axial thrust provided by the springs Q = 1446.9 N

5
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.2

Example 2: An automobile single plate clutch consists of two pairs

of contacting surfaces. The inner and outer radii of friction plate are
120 mm and 250 mm respectively. The coefficient of friction is 0.25
and the total axial force is 15 kN. Calculate the power transmitting
capacity of the clutch plate at 500 rpm using (i) uniform wear theory
and (ii) uniform pressure theory (AU-May 2013)

Given data: r = 0.12 m, R = 0.25 m, μ = 0.25, Q = 15 kN, N = 500 rpm

(i) For uniform wear theory

R  r 0 . 25  0 . 12
Mean radius rm    0 . 185 m
2 2

Torque transmitted by the clutch for both side effective

M t
 2  Q rm  2  0 . 25  15000  0 . 185  1387 . 5 Nm
6
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.2

Power transmitted by the clutch

2 N M
P 
t

60
2  3 . 14  500  1387 . 5
P   72615 . 2 W
60

(ii) For uniform pressure theory

Mean radius
2  R  r  2  0 . 25  0 . 12 
3 3 3 3

rm   2      0 . 1926 m
   
3  R  r  0 . 12
2 2 2
 3  0 . 25 

Torque transmitted by the clutch for both side effective

M t
 2  Q rm  2  0 . 25  15000  0 . 1926  1444 . 5 Nm
7
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.2

Power transmitted by the clutch

2 N M
P 
t

60
2  3 . 14  500  1444 . 5
P   75595 . 5 W
60

Answer
Power transmitted by the clutch
(i) For uniform pressure condition = 75.6 kW
(ii) For uniform wear condition = 72.6 kW

8
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.2

Example 3: A power of 20 kW is to be transmitted through a cone

clutch at 500 rpm. For uniform wear conditions, find the main
dimensions of clutch and shaft. Also, determine the axial force
required to engage the clutch. Assume coefficient of friction as
0.25, the maximum normal pressure on the friction surface is not
to exceed 0.08 MPa and the design stress for the shaft material as
40 MPa (AU-Nov 2015, May 2015, AU-May 2006)

Given data: Power = 20 kW, N = 500 rpm, μ = 0.25, P = 0.08 MPa,

Ps = 40 MPa

Torque transmitted by the clutch

Power  60 20000  60
M t
   382 Nm
2 N 2   500

9
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.2

Clutch shaft diameter



3
M t
d Ps
16
16 M 16  382
d  
t 3
3
 Ps 3 . 14  40  10
6

d  0 . 037 m  37 mm

Dimensions of the clutch using uniform wear theory

Assume face width b = rm/2, and half cone angle α = 12o

R  r
Mean radius rm 
2

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 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.2

For uniform wear theory

 2 π μ P rm b
2
M t

rm
382  2 π  0.25  0.8  10  rm 
6 2

2
382
rm  3  0 . 182 m
63000
R  r
rm   0 . 182 m
From the triangle 2
R  r  0.364
R  r
sin  
b
Face width
rm 0 . 182 b = rm/2 = 0.182/2
R  r  sin    sin 12   0 . 019
2 2 b= 0.091 m

Solving the two equations: R = 0.1915 m and r = 0.1725 m

11
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.2

Axial normal force

Q P  2 π r m b sin 
Qn  
sin  sin 
Q n  0 . 08  10  2 π  0.182  0.091  8320 . 75 N
6

Axial force to engage the clutch

QE = Qn (μ cos α + sin α)
QE = 8320.75 x (0.25 x cos 12 + sin 12) = 3764.7 N
Answer
Shaft diameter = 37 mm
Inner radius of clutch = 17.25 cm
Outer radius of clutch = 19.15 cm
Width of clutch = 9.1 cm
Axial force to engage the clutch = 3764.7 N
12
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.2

Example 4: A cone clutch has a cone angle of 11.5o, a mean

frictional diameter of 320 mm and face width of 60 mm. The clutch
is to transmit a torque of 200 Nm. The coefficient of friction is 0.26.
Find the activating force and pressure using the assumption of
uniform pressure (AU-May 2011)
Given data: rm = 0.32 m, b = 0.06 m, Mt = 200 Nm, μ = 0.26, α = 11.5o

For uniform pressure theory, the torque transmitted

μ Q rm
M t

sin α

The axial force

sin α M  sin 11 . 5   200
Q    479 . 25 N
t

μ rm 0 . 26  0 . 32
13
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.2

The total pressure on the clutch

Q 479 . 25
P    24961
2
N/m
rm b 0 . 32  0 . 06

Answer
Activating force Q = 479.25 N
Total pressure on the clutch P = 24961 N/m2

14
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.2

Example 5: An engine developing 45 kW at 1000 rpm is fitted with a

cone clutch built inside the flywheel. The cone has a face angle of
12.5o and a maximum mean diameter of 500 mm. The coefficient
of friction is 0.2. The normal pressure on the clutch face is not to
exceed 0.1 N/mm2. Determine the face width required and the
axial spring force necessary to engage the clutch (AU-Nov. 2006)

Given data: Power = 45 kW, N = 1000 rpm, α = 12.5o, μ = 0.2,

rm = 0.5 m, P = 0.1 N/mm2

Torque transmitted by the clutch

P  60 45000  60
M t
   430 Nm
2 N 2   1000

15
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.2

Axial spring force required for uniform wear theory

sin α M  sin 12 . 5   430
Q    930 . 7 N
t

μ rm 0 .2  0 .5

Face width of cone clutch assuming uniform wear theory

Q
b 
2 π μ P r m sin 

930 . 7
b   0 . 068 m
2   0 . 2  0 . 1  10  0 . 5  sin 12 . 5
6

Answer
Face width of clutch = 6.8 cm
Axial spring force Q = 930.7 N
16
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Thank you for watching

Please post your comments

Contact: k.kannan@aamec.edu.in
WhatsApp: 944261659

18
 Design of
Transmission
Systems

Dr. K. Kannan
Professor Mechanical Engineering
Anjalai Ammal Mahalingam Engineering College
Kovilvenni – 614 403

19
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.3

Topic Problems in clutch design

Design of plate clutches – Axial clutches – Cone

Recap clutches – Internal expanding rim clutches –
electromagnetic clutches

Learning Outcome
At the end of the lecture, the student will be able to
1. Solve problems in single plate, cone and multi plate clutch
under uniform pressure and wear conditions
20
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.3

Example 6: A multiple disc clutch consisting of steel and bronze

plates is to transmit 10 kW at 1000 rpm, the inner and outer
diameter of discs being 90 and 160 mm respectively. The
engagement factor may be taken as 1.25. The coefficient of friction
between the contacting plates is 0.18 and maximum intensity of
pressure 0.3 N/mm2. Find the required number of steel and bronze
plates using uniform wear conditions (AU-Nov 2011)

Given data: Power = 10000 W, N = 1000 rpm, μ = 0.18, Engagement

factor = 1.25, r = 0.045 m, R = 0.08 m, P = 0.3 x 106 N/m2
For uniform wear conditions, the mean radius

R  r 0 . 08  0 . 045
rm    0 . 0625 m
2 2

21
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.3
Torque transmitted by the clutch
P  60 10000  60
M t
   95 . 5 Nm
2π N 2   1000

Design torque of the clutch

(Mt) = Mt x Engagement factor
= 95.5 x 1.25 = 119.4 Nm

Axial thrust to be provided for uniform wear theory

Q = 2 π pa r (R – r)
Q = 2 x 3.14 x 0.3 x 106 x 0.045 x (0.08 – 0.045) = 2967.3 N/m2

Torque transmitted per pair of frictional surfaces

(Mt)1 = μ Q rm = 0.18 x 2967.3 x 0.0625 = 33.38 Nm

22
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.3

Number of pairs of friction surfaces

Design tor que of the clutch
z 
Torque transmitt ed per pair of clutch
M t  119 . 4
z    3 . 57  4
 M t 1 33 . 38

Number of plates = z + 1 = 4 + 1 = 5
Number of steel plates = 3
Number of bronze plates = 2

23
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.3

Example 7: A plate clutch has three discs on the driving shaft and
two discs on the driven shaft, providing four pair of contact
surfaces. The outside diameter of the contact surface is 240 mm
and inside diameter 120 mm. Assuming uniform pressure and
coefficient friction 0.3, find the total spring load pressing the plates
together to transmit 25 kW at 1600 rpm. (AU-Nov. 2009)
Given data: z1 = 3, z2 = 2, z = 4, R = 0.12 m, r = 0.06 m, Uniform
pressure, μ = 0.3, Power = 25 kW, N = 1600 rpm
Torque transmitted by the clutch
P  60 25000  60
M t
   149 . 3 Nm
2π N 2   1600

Torque transmitted by a pair of friction surfaces

M t  149 . 3
 M t 1    37 . 325 Nm
z 4 24
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.3

For uniform pressure conditions, the mean radius

2  R  r  2  0 . 12  0 . 06 
3 3 3 3

rm   2      0 . 0933 m
   
3  R  r  0 . 06
2 2 2
 3  0 . 12 

The spring force acting on the clutch plates

 M t 1 37 . 325
Q    1333 . 5 N
 rm 0 . 3  0 . 0933

Answer
Total spring force acting on the clutch plates Q = 1333.5 N

25
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.3

Example 8: A multi disk clutch consists of five steel plates and four
bronze plates. The inner and outer diameters of friction disks are
75 mm and 150 mm respectively. The coefficient of friction is 0.1
and the intensity of pressure is limited to 0.3 N/mm2. Assume the
uniform wear theory, calculate the required operating force and
power transmitting capacity at 750 rpm. (AU-May 2008)
Given data: z1 = 5, z2 = 4, r = 0.0375 m, R = 0.075 m, μ = 0.1, P = 0.3
N/mm2, N = 750 rpm
For uniform wear conditions, the mean radius
R  r 0 . 075  0 . 0375
rm    0 . 05625 m
2 2

Axial thrust to be provided for uniform wear theory

Q = 2 π pa r (R – r)
Q = 2 x 3.14 x 0.3 x 106 x 0.0375 x (0.075 – 0.0375) = 2649.4 N/m
26
2
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.3

Torque transmitted per pair of frictional surfaces

(Mt)1 = μ Q rm = 0.1 x 2649.4 x 0.05625 = 14.9 Nm

Number of pairs of frictional surfaces

z = z1 + z2 – 1 = 5 + 4 – 1 = 8

Total torque transmitted by the clutch

(Mt) = z (Mt)1 = 8 x 14.9 = 119.2 Nm

Power transmitting capacity of clutch

2 π N M  2  3.14  750  119.2
P    9357 W  9.357
t
kW
60 60

Answer
Operating force Q = 2649.4 N
Power transmitting capacity = 9.36 kW 27
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.3

Example 9: A hydraulically operated clutch is to be designed for an

automatically operated lathe. Determine the number of plates and
the operating force required for a clutch which is to transmit a
torsional moment of 35 Nm under normal operating conditions.
The clutch is to be designed to slip under 300 percent of rated
torsional moment to protect the gears and other parts of the drive.
The limit for the diameter of the friction surface due to space
limitations are 100 mm and 62.5 mm. This clutch is to operate in an
oily atmosphere. (AU-Nov 2005, Nov 2012, May 2014)

Given data: Mt = 35 Nm, slip = 300%, R = 0.05 m, r = 0.03125 m

For uniform wear conditions (oily atmosphere), the mean radius

R  r 0 . 05  0 . 03125
rm    0 . 040625 m
2 2
28
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.3

Allowable pressure for steel plate (PSG data book page7.89)

Pa = 6 kgf/cm2 = 6 x 105 N/m2

Coefficient of friction μ = 0.25 assumed

Axial thrust to be provided for uniform wear theory

Q = 2 π pa r (R – r)
Q = 2 x 3.14 x 6 x 105 x 0.03125 x (0.05 – 0.03125) = 2207.8 N/m2

Torque transmitted per pair of frictional surfaces

(Mt)1 = μ Q rm = 0.25 x 2207.8x 0.040625 = 22.42 Nm

Design torque of clutch (Mt) = 3 x Mt = 3 x 35 = 105 Nm

29
 Dr. K. Kannan Problems in clutch design Lecture No: DTS 10.3

Number of pairs of friction surfaces

Design tor que of the clutch
z 
Torque transmitt ed per pair of clutch
M t  105
z    4 . 68  5
 M t 1 22 . 42

Number of plates = z + 1 = 5 + 1 = 6

Answer
The number of plates = 6
The operating force required = 2207.8 N

30
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31
Thank you for watching

Please post your comments

Contact: k.kannan@aamec.edu.in
WhatsApp: 9442616597

32