Dr P Ramkumar/DTS/Data Sheet/2022

Page 1 of 25

Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm

Data Sheet – EndSemester Exam

ME6222 Design of Mechanical Transmission Systems

Table 1: Gear Speed Step Ratio and basic series

Table 2: Gear Speed Selection based on Step Ratio

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Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm

Table 3: Recommended Values of φ in Machine Tools

Machine Tools Value ofφ

Heavy duty m/c tools and automats 1.12
Large to medium size general purpose m/c tool and automats 1.26
Medium size general purpose/mc tools 1.41
Medium to small size general purpose m/c tools 1.58

FOR SPUR GEARS:

Table 4: Minimum number of teeth

Select number of teeth in such a way ε > 1.1; Forhigh-speed gears ε > 1.5; For gears
without correction z1 min ≥ z1. External gears z1 + z2 ≥ 24; Internal gears z2 – z1
≥ 10.

Operating Condition Z1 min

Gears running at high speeds (15 m/s and above) and having high load 16
Gears running at medium speeds (3 – 15 m/s) 12
Gears running at low speeds or low loads (< 3 m/s) 10
(gears used for secondary purposes)
Precision gearing - First step 20-25
-Second step 14 – 17
-With heavy loads (Turbine) 33

Table 5: Gear Materials

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Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm

Material Specification Condition  ut BHN h b

MPa MPa MPa
Cast Steels GS 52.1 Annealed 520 150 370 100
GS 60.1 - do - 600 175 540 120
Machine St 42 Annealed 420 – 500 125 340 110
construction St 50 - do - 500 – 600 150 400 130
steels St 60 - do - 600 – 700 180 450 150
St 70 - do - 700 – 800 208 520 170
Thorough C 45 Quenched 650 – 800 185 – 540 160
hardening steels C 60 and 700 – 800 210 610 180
37Mn Si5 hardened 700 – 800 220 650 210
37Mn Si5 800 – 950 260 710 220
34Cr4 750 – 900 260 760 210
42CrMo4 950 – 1100 340 760 220
35NiCr8 1000 – 1600 400 1120 230
Carburizing C 10 Hardened 420 – 520 590 1600 140
steels C 15 500 – 650 637 1760 150
16MnCr5 800 – 1100 650 1820 300
15CrNi6 900 – 1200 650 1820 310
20MnCr5 1000 – 1300 650 1820 330
18CrNi8 1200 – 1450 650 1820 330
Flame or C 45 Hardened 650 – 800 595 1670 220
induction 37Mn Si5 - do - 900 – 1050 560 1580 240
hardening steels 53Mn Si4 - do - 900 – 1100 615 1710 250
41Cr4 - do - 900 – 1100 587 1650 250
Cyanided steels 41Cr4 Hardened 1400 – 1800 595 1670 220
37Mn Si5 - do - 1500 – 1900 550 1550 250
Grey cast iron CI 18 180 170 240 30
CI 28 260 210 320 40
Note: In general, when the surface hardness of materials BHN is less than 350, the difference
in surface hardness’s of pinion and wheel must be greater than 30

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Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm

Module Calculation:

Based on bending strength Based on pitting strength

 2TK TotalS F 
m 3   
 ( b )YZ 
Where,
T = Torque (Nm) Y = Lewis Form Factor
KTotal = Total Rating Factors Z = No of teeth
SF = Factor of Safety for Bending (σb) = Bending stress (N/m2)
stress
SH = Factor of Safety for contact (σc) = Contact stress (N/m2)
stress ZE = elastic coefficient, (N/m2)1/2

Based on Centre Distance:

T (mg + 1) (Z E S H )2 3 (K
4

a3 3 ) 2

4 b ( c ) 2
TOTAL c

Where,
ig =gear ratio b = face width (mm)

d = pitch diameter (mm) a = centre distance (m)

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Page 5 of 25

Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm

Table 6: Standard modules, mm IS 2535 / DIN 780

Preferred 1 1.25 2 2.5 3 4 5 6 8 10 12 16 20

2nd Choice 1.125 1.375 1.75 2.25 2.75 3.5 4.5 5.5 7 9 14 18 --

Chart: Face width diameter relationship for passenger car

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Page 6 of 25

Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm
Table 7: Ψ Factor for between facewidth (b), centre distance (c) andmodule (m)
S.No Accuracy and Mounting Support ψ = b/m ψc = b/c
1 Unground gear, mounting shaft supported at one end 6-8 Upto 0.1
only
2 Low accuracy, mounting shaft supported at both ends, 10-15 0.12
operates
3 Precision, mounting shaft supported at both ends, 15-20 0.15
operates less than 3000 rpm
4. Precision, mounting shaft supported at both ends, 16-24 0.3
operates more than 3000 rpm

Figure 1: Lewis form factor

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Page 7 of 25

Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm

Table 8: Elastic Coefficient

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Page 8 of 25

Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm

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Page 9 of 25

Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm
Shaft Design
 2 
 32 N f 3 T  
2
 Ma 
d =
3
 Kb  +  Kt m 
 
   Se  4  Sy  
 

Table 9: Shaft materials

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Page 10 of 25

Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm

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Page 11 of 25

Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm

Table 10: Combined shock and fatigue factors for ASME shaft design equation

Table 11: Standard size for solid shafts

Diameter (mm) Increment (mm)

Up to 25 0.5
25 to 50 1
50 to 100 2
100 to 200 5

Table 12: Shaft slopes based on rigidity

Bearing Types Slopes (radians)

Tapered Roller 0.0005-0.0012
Cylindrical Roller 0.0008-0.0012
Deep-groove ball 0.001-0.003
Spherical ball 0.026-0.052
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Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm
Self-align ball 0.026-0.052
Uncrowned spur gear < 0.0005

Table 13: Shaft traverse deflections

Diametral Pitch (No of teeth/cm) Deflections (mm)

Spur gear, P < 4 0. 25
Spur gear, 5< P < 8 0.125
Spur gear, 9 < P < 20 0.075

Bearing Calculations:

Dynamic Load Carrying Capacity (C10)

n
C 
L10 =   L10 = (60 * N * L10h ) / 10 6
P
Where, L10 =rated bearing life in million revolutions
C = dynamic load carrying capacity (N) P = equivalent dynamic load (N)
n = 3 for ball bearings n = 10/3 for roller bearings
N = shaft speed in RPM L10h = rated bearing life in hours

Equivalent Dynamic Load (P)

P = XVFr + YFa
Fr= radial load in (N) Fa = thrust load in (N)
V = rotation factor, V = 1 if inner race rotates V = 1.2 if outer race rotates
X and Y are radial and thrust factors, these values given in the manufacturer’s catalogue

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Page 13 of 25

Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm

Table 14: Equivalent Radial Factors for Ball Bearings

Lubrication Selection:

Recommended lubrication based on average speed, using AGMA equation,

7000
40 =
V
Where,
V = Average Pitch line velocity of gear (ft/min)
υ40= Kinematic Viscosity of oil (cSt) at 40°C
V = 0.262 d*N
d = pitch diameter (inch) and N = speed (RPM)

Table 15: Dimensions and Basic Load Rating for Single Row, Deep groove, and
Angular Contact Bearings

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Page 14 of 25

Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm

Table 16: Dimensions and Basic Load Rating for Cylindrical Bearings

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Page 15 of 25

Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm

Figure 2: Gear oils with SAE standard based on temperature

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Page 16 of 25

Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm

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Page 17 of 25

Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm
Power loss in gear teeth (Pg):

 0.1 0.3 
Pg = P *  + 
 Z1 cos  V + 0.2 

P = Power input (W) Pg = Power loss in gear teeth engagement (W)

Z1 = Number of gear teeth for drive  = Helix angle
V = Velocity of gear (m/s)

Power loss in bearing (Pb)

Tb = 0.5 *  * P * d Pb = 10 −4 * Tb * N

Tb = frictional torque (Nm) P = Equivalent load (N) or 10% of C (dynamic l.c.c)

d = bearing bore diameter (mm) µ = coefficient of friction, see table No: 17
N = Shaft speed (rpm) Pb = Power loss in bearing (W)

Table 17: Coefficient of friction of bearings(from SKF Catalogue)

Bearing Type Coefficient of Friction

Deep groove ball bearings 0.0015
Angular contact ball bearings
– single row 0.0020
– double row 0.0024
– four-point contact 0.0024
Self-aligning ball bearings 0.0010
Cylindrical roller bearings
– with a cage. when Fa ≈ 0 0.0011
– full complement. when Fa ≈ 0 0.0020
Needle roller bearings with a cage 0.0020
Tapered roller bearings 0.0018
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Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm
Spherical roller bearings 0.0018
CARB toroidal roller bearings with a cage 0.0016
Thrust ball bearings 0.0013
Cylindrical roller thrust bearings 0.0050
Needle roller thrust bearings 0.0050
Spherical roller thrust bearings 0.0018

Power loss in seals (Ps)

Ps = Ts * 
Ts = Fr r
Where,

Ps = Power loss in seals (W)

Ts = frictional torque in seal (Nm)
ω = angular velocity of the shaft
μs = seal friction
Fr = Radial lip load (N)
r = radius of the shaft (m)

Table 18: Thickness parameter of gearbox housing

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Page 19 of 25

Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm
The above table values for lower half thickness (t1) of gearbox housing
t2 = 0.8 to 1t1 t3 = 1.5t1 t4 = 2t1

Where,
t2 = wall thickness of upper half
t3 = thickness of mating flanges of casing
t4 = thickness of bottom flange

Brake Design Dynamic Analysis Equations for two-axle vehicle

The normal reaction force at front axil

𝑊𝑙2 + ℎ (𝑃𝑏 + µ𝑟 𝑊)
𝑁𝐹𝐴 =
𝐿
𝑊𝑙 −ℎ (𝑃𝑏 + µ𝑟 𝑊)
The normal reaction force at rear axil 𝑁𝑅𝐴 = 1 𝐿
Maximum braking Force at front axil
𝑙2 + ℎ(µ𝑠 + µ𝑟 )
(𝑃𝑏𝑚𝑎𝑥 )𝐹 = µ𝑠 𝑊 [ ]
𝐿
𝑙 −ℎ(µ +µ )
Maximum braking Force at rear axil (𝑃𝑏𝑚𝑎𝑥 )𝑅 = µ𝑠 𝑊 [ 1 𝐿𝑠 𝑟 ]
Optimum braking effort
𝐾𝑏𝑓 𝑙2 + ℎ(µ𝑠 + µ𝑟 )
=
𝐾𝑏𝑟 𝑙1 − ℎ(µ𝑠 + µ𝑟 )
𝑙
𝑎 (µ𝑠 𝐿2 + 𝐾𝑏𝑓 µ𝑟 )
( ) =
𝑔 𝐹 ℎ
(𝐾𝑏𝑓 − µ𝑠 𝐿)
𝑙
𝑎 (µ𝑠 𝐿1 + (1 − 𝐾𝑏𝑓 )µ𝑟 )
( ) =
𝑔 𝑅 ℎ
((1 − 𝐾𝑏𝑓 ) + µ𝑠 𝐿)
µ𝑠 = 𝑅𝑜𝑎𝑑 𝑎𝑑ℎ𝑒𝑠𝑖𝑜𝑛 µ𝑟 = 𝑅𝑜𝑙𝑙𝑖𝑛𝑔 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒
L = Wheelbase (m) h = Distance from ground to the centre of mass of the vehicle (m)
𝑙1 = 𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑓𝑟𝑜𝑚 𝑓𝑟𝑜𝑛𝑡 𝑎𝑥𝑙𝑒 𝑡𝑜 𝑡ℎ𝑒 𝑐𝑒𝑛𝑡𝑒𝑟 𝑜𝑓 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑣𝑒ℎ𝑖𝑐𝑙𝑒 (m)

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Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm
𝑙2 =

𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑓𝑟𝑜𝑚 𝑟𝑒𝑎𝑟 𝑎𝑥𝑙𝑒 𝑡𝑜 𝑡ℎ𝑒 𝑐𝑒𝑛𝑡𝑒𝑟 𝑜𝑓 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑣𝑒ℎ𝑖𝑐ℎ𝑙𝑒 (m)

Pivoted Shoe Drum Brake Torque Analysis

 μC 
 
S =  R 
leading   
 α ( ) − sinα cosα 
h  o 180 o 3  h 
− μ1 +  cos(α /2)cos(α /2) 
R  4sin( α /2)sin( α /2)    R  o 3 
 o 3 
 

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Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm
 μC 
 
S =  R 
trailing   
 α ( ) − sinα cosα 
h  o 180 o 3  h 
+ μ1 +  cos(α /2)cos(α /2) 
R  4sin( α /2)sin( α /2)    R  o 3 
 o 3 
 

Where,
C=distance between the actuation point and the pivot point of the shoe (m)
R= the drum radius (m);

h= is the distance from the center of the brake to the pivot center (m);

α
o = the angle subtended by the lining arc length (degree);
α
1 = angle between the straight line connecting centre of drum and pivot point to beginning
of the brake lining (degrees)
α
2 = angle between the straight line connecting centre of drum and pivot point to ending of
the brake lining (degrees)

α = α + 2α α = α -α
3 o 1 o 2 1

Table 19: SAE coefficient of friction code for Brake Linings

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Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm

Temperature Analysis for Single stop braking:

1 1
5 2 𝑄(𝑡𝑏 )2
𝑇𝑚𝑎𝑥,𝐿 − 𝑇𝑖 = ( )
18 (𝜌𝑐𝑘)12
Where,
Ti = Initial Temperature (K)
tb = time to stop vehicle (s)
t = time to reach maximum surface temperature (s) and
t = tb/2 (s)

Temperature Analysis for repeated braking:

The relative brake temperature before the nth brake application,

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Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm
−ℎ𝑅 𝐴𝑅 𝑡𝑐
( )
{1 − 𝑒 (𝑛𝑎−1)ℎ𝑅𝐴𝑅𝑡𝑐/(𝜌𝑅𝐶𝑅𝑉𝑅 ) } {𝑒 𝜌𝑅 𝐶𝑅 𝑉𝑅 } {∆𝑇}

[𝑇(𝑡) − 𝑇∞]𝑏 = ℎ 𝐴 𝑡
( 𝑅 𝑅 𝑐)
1−𝑒 𝜌𝑅 𝐶𝑅 𝑉𝑅

The relative brake temperature after the nth brake application,

(−𝑛𝑎 ℎ𝑅 𝐴𝑅 𝑡𝑐 )
[1 − 𝑒 (𝜌𝑅 𝐶𝑅 𝑉𝑅 ) ] {∆𝑇}

[𝑇(𝑡) − 𝑇∞]𝑎 = ℎ 𝐴 𝑡
(− 𝑅 𝑅 𝑐 )
1−𝑒 𝜌𝑅 𝐶𝑅 𝑉𝑅

The temperature increment,

𝑄𝑡𝑏
∆𝑇 =
𝜌𝑅 𝐶𝑅 𝑉𝑅

Temperature Analysis for continued braking:

−(ℎ𝑅 𝐴𝑅 𝑡𝑏
𝑄
𝑇(𝑡) = [𝑇𝑖 − 𝑇∞ − ℎ ] 𝑒 𝜌𝑅𝐶𝑅𝑉𝑅) +T∞ + 𝑄/ℎ𝑅 𝐴𝑅
𝑅 𝐴𝑅

Where,
Q = braking power absorbed
T∞ = ambient Temperature (K)
T = temperature at time t, (K)
na = number of brake application
CR = specific heat (Nm/kgK)
VR = rotor volume (m3)
ρR = rotor density (kg/m3)
hR = heat transfer coefficient of rotor (W/Km2)

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Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm

Table 20: Properties of brake lining and disc/drum materials

Lining Pad Drum/Disc Units

Density 2034 2595 7228 Kg/m3
Specific heat 1256 1465 419 J/kgK
Thermal conductivity 1.167 1.21 48.5 W/mK
Diffusivity 4.56e-07 3.183e-07 1.6e-05 m2/s

Heat transfer coefficient(𝛼)

𝛼 = 12.8 + 2.9 ∗ 𝑉
Where,𝑉 = 𝜔 ∗ 𝑅𝑐 𝑅𝑐 = 𝑅𝑎𝑑𝑖𝑢𝑠 𝑜𝑓 𝑐𝑙𝑢𝑡𝑐ℎ

Table 21: Friction Materials for Clutch

Friction Materials Against Dynamic Dynamic Max Max

Steel or CI CoF CoF Pressure Temperature
Dry Oil kPa ºC
Woven asbestos–CI 0.3-0.6 0.1-0.2 345-690 204-260

Moulded asbestos–CI 0.2-0.5 0.08-0.12 1030-2070 204-260

Bronze–sintered metal–CI 0.1-0.4 0.05-0.1 1030-2070 232-677

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Clutch Design

Clutch assembly dimensions

Pressure plate thickness = 15 mm

Clutch plate thickness = 10-12 mm
Cover thickness =10 mm
Bronze–sintered metal–steel 0.1-0.3 0.05-0.1 690-720 260

25