Module 3 Clutches

ME 211: Machine Design
Module 3
Design of Clutches: Types of clutches, Disc Clutches, Clutch material, and

selection
Design of brakes : Types of Brakes, Shoe, Band and Disk Brakes, Brake selection
and specification, Brake materials
Clutches
The clutch is a mechanical device, which is used to connect or disconnect the source
of power from the remaining parts of the power transmission system at the will of the
operator.
https://www.youtube.com/watch?v=lqo0_StXf4M
https://www.youtube.com/watch?v=devo3kdSPQY
Types of Clutches
(i) Positive contact Clutches
Types of Clutches
(ii) Fluid Clutches
https://www.youtube.com/watch?v=11Q4g-oOLr8
Types of Clutches
(iii) Electromagnetic Clutches
https://www.youtube.com/watch?v=OztP3uFlUlI
Types of Clutches
(iv) Friction Clutches
In these clutches, power

transmission is achieved
by means of friction
between contacting
surfaces.
Single plate clutches are used in applications

where large radial space is available, such as
trucks and cars.
MULTI-DISK CLUTCHES
Multi-disk clutches are used in applications where compact construction

is desirable, e.g., scooter and motorcycle.
Number of pairs of contacting surfaces, z = (z1 + z2 – 1)

𝑧1 = number of disks on driving shaft
𝑧2 = number of disks on driven shaft
Types of Clutches
(i) Positive contact Clutches:- They include square jaw clutches; spiral jaw clutches and
toothed clutches. In these clutches, power transmission is achieved by means of interlocking
of jaws or teeth. Their main advantage is positive engagement and once coupled, they can
transmit large torque with no slip, but have heavy shock.
(ii) Fluid Clutches and Couplings In these clutches, power transmission is achieved by
means of hydraulic pressure. A fluid coupling provides extremely smooth starts and absorbs
shock.
(iii) Electromagnetic Clutches They include magnetic particle clutches, magnetic hysteresis
clutches and eddy current clutches. In these clutches, power transmission is achieved by
means of the magnetic field. These clutches have many advantages, such as rapid response
time, ease of control, and smooth starts and stops.
(iv) Friction Clutches They include single and multi-plate clutches, cone clutches and
centrifugal clutches. In these clutches, power transmission is achieved by means of friction
between contacting surfaces. This chapter is restricted to friction clutches.
The main advantages of friction clutch are as follows:
(i) The engagement is smooth.
(ii) Slip occurs only during engaging operation and once the clutch is engaged, there is no slip
between the contacting surfaces. Therefore, power loss and consequent heat generation do not
create problems, unless the operation requires frequent starts and stops.
(iii) In certain cases, the friction clutch serves as a safety device. It slips when the torque
transmitted through it exceeds a safe value. This prevents the breakage of parts in the
transmission chain.
Friction Materials
Torque Transmitting Capacity
D = outer diameter of friction disk (mm)
d = inner diameter of friction disk (mm)
p = intensity of pressure at radius r (N/mm2)
F = total operating force (N)
T = torque transmitted by the clutch (N-mm) 𝑭
Two theories are used to obtain the torque capacity of the clutch.
(i) Uniform Pressure Theory
(ii) Uniform Wear Theory

Uniform Pressure Theory
According to the first theory, it is assumed that the pressure remains constant over the
entire surface area of the friction disk.
𝑭
Uniform Wear Theory
According to the second theory, it is assumed that the wear is uniformly distributed
over the entire surface area of the friction disk.
𝑭
Therefore, the torque transmitting capacity can be increased by three methods:
(i) Use friction material with a higher coefficient of friction
(ii) Increase the plate pressure
(iii) Increase the mean radius of the friction disk
Conclusions
❖ The uniform-pressure theory is applicable only when the friction lining is new.
❖ The uniform-wear theory is applicable when the friction lining gets worn out.
❖ The friction radius for new clutches is slightly greater than that of worn-out
clutches.
❖ The torque transmitting capacity of new clutches is slightly more than that of
worn-out clutches.
❖ A major portion of the life of friction lining comes under the uniform wear
criterion.
❖ It is more logical and safer to use uniform wear theory in the design of clutches
Summary
The only important thing to understand in friction clutches is the knowledge when to
apply which theory.
✓ If a question mentions that clutch is new, use uniform pressure theory.
1 𝐷3 −𝑑 3 𝑅𝑓 : Mean radius of friction disk
Torque transmitting capacity, 𝑇 = 𝑧𝜇𝐹𝑅𝑓 ; 𝑅𝑓 =
3 𝐷2 −𝑑 2
𝜋𝑝 2
𝐹= (𝐷 − 𝑑2 )
4
For single plate clutch, Number of pairs of contacting surfaces, 𝑧 = 1 𝑑
𝑧1 = number of disks on driving shaft 𝐷

For multi-disk plate clutch, 𝑧 = 𝑧1 + 𝑧2 − 1
𝑧2 = number of disks on driven shaft
✓ If a question mentions that clutch is worn-out, use uniform wear theory.

𝐷+𝑑 𝜋𝑝𝑎 𝑑(𝐷 − 𝑑)
Torque transmitting capacity, 𝑇 = 𝑧𝜇𝐹𝑅𝑓 ; 𝑅𝑓 = 𝐹=
2
4
✓ If a question mentions that clutch is old, use uniform wear theory.
✓ If a question mentions that clutch is being used for power transmission, use
uniform wear theory.
✓ If a question mentions nothing and you feel stuck, then also use uniform wear
theory.
Numerical 1
A disk clutch is designed to transfer 5 kW at 2000 rpm. The friction lining of disk has a
friction coefficient of 0.25, with bore radius of 25 mm. Assuming uniform contact
pressure of 1 MPa, calculate the outside radius of the friction lining?
Solution
Numerical 2
A disc clutch with a single friction surface has coefficient of friction of 0.3. The
maximum pressure which can be imposed on the friction material is 1.5 MPa. The
outer and inner diameter of the clutch plate are 200 mm and 100 mm, respectively.
Assuming uniform wear theory for the clutch plate, find the maximum torque (in N-m)
that can be transmitted?
Solution
Numerical 3
A multi-disk clutch consists of five steel plates and four bronze plates. The inner and
outer diameters of the friction disks are 75 and 150 mm respectively. The coefficient of
friction is 0.1 and the intensity of pressure on friction lining is limited to 0.3 N/mm2.
Assuming uniform wear theory, calculate:
(i) the required force to engage the clutch
(ii) power transmitting capacity at 750 rpm.
Solution
Numerical 4
A friction disc of a single-plate clutch has an inner and outer radii of 20 mm
and 40 mm, respectively. The coefficient of friction in the disc lining varies
radially as μ = 0.01r, where r is in mm. The clutch should deliver a friction
torque of 18.85 kN-mm. Find the pressure (in MPa) on the disc as per uniform
pressure theory.

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ME 211: Machine Design

Design of Clutches: Types of clutches, Disc Clutches, Clutch material, and

In these clutches, power

Single plate clutches are used in applications

Multi-disk clutches are used in applications where compact construction

Number of pairs of contacting surfaces, z = (z1 + z2 – 1)

(i) Uniform Pressure Theory

(ii) Uniform Wear Theory

For single plate clutch, Number of pairs of contacting surfaces, 𝑧 = 1 𝑑

𝑧1 = number of disks on driving shaft 𝐷

✓ If a question mentions that clutch is worn-out, use uniform wear theory.

✓ If a question mentions that clutch is old, use uniform wear theory.

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