Friction Clutches Machine Design 2

T = nμF rf – Eq. 2

Friction Clutches n
μ
–
–
number of mating surfaces
coefficient of friction
F – axial force, N
rf – friction radius, m
Clutches are used to connect shafts to a driving
mechanism such as a motor, engine, or line shaft, and to Multiple-disk clutches are usually of the
diskonnect them at will. They may be classed as (1) multiple-plate type in which one set of disks is splined to
friction clutches in which the driving force is transmitted one shaft and the other set, alternating with the first, is
by the friction of surfaces in contact, (2) jaw clutches in splined to the other shaft. Pressure on the clutch pack is
which jaws, dogs, or teeth in the two elements interlock, usually applied by one or more springs which are either
(3) hydraulic clutches (fluid couplings) in which torque is adjusted to impose a steady pressure on the disk or which
transmitted hydrodynamically through change of may be regulated for varying pressure.
momentum of a moving fluid, and (4) electromagnetic
clutches in which torque is transmitted across an air gap A multiple disk clutch is shown below. The plates
through the creation of an electromagnetic field. In shown as A are usually steel and are set on splines on
addition, there are overrunning or freewheeling clutches shaft C to permit axial motion (except for the last disk).
which permit torque transmission in one direction only. The plates shown as B are usually bronze and are set in
splines of member D.
Heat Generation and Friction A B
Friction clutches generate heat as a result of
relative motion of the parts, but the amount of sliding is
D
F
not ordinarily as great as in a brake. It is quite customary R C
2
in the analysis of a clutch to picture that the parts are in
impending motion with respect to each other, although F
one must not lose sight of the fact that transmission of r F
power through friction usually involves some slip. For this
2
reason, when it is necessary to have positive power
transmission one must resort to a positive device, as a jaw
type of clutch.
multiple disk clutch
Design values of the coefficient of friction for
clutches should probably be somewhat lower than those The number of pairs of surfaces transmitting
for breaks, say about 0.1 to 0.3. The following values may power is one less than the sum of steel and bronze disks,
be used in clutch calculations: for greasy leather on cast and is also an even number if the design is such that no
iron about 0.20 or 0.25, leather on metal that is quite oily thrust bearings are needed. In calculating the torque
0.15, metal and cork on oily metal 0.32; the same on dry capacity of a multiple disk clutch, the torque calculated is
metal 0.35; metal on dry metal 0.15; disk clutches having multiplied by the number of mating surfaces.
lubricated surfaces 0.10. The normal pressure between the
disks ranges from 100 to 400 kPa in extreme cases. Mean Friction Radius, rf
New clutch – uniform pressure disk clutch.
Disk or Plate Clutch When a clutch is new, it is perhaps true that the pressure
may be uniform. If the surfaces are relatively rigid, the
Disk or plate clutch are two flanges one keyed outer portion where the velocity is high, will wear more
rigidly to the driving shaft, and the other fitted to the drive than the inner portion. Uniform pressure assumption
shaft. The amount of torque transmitted is dependent would be more appropriate where the plates are flexible to
upon the axial pressure distribution, the dimensions of the permit deflection when wear occurs.
friction surfaces and the coefficient of friction.

Power Transmitted

P = 2πTf – Eq. 1
rf =
(
2 R3 −r 3
3 R2 −r 2 ) – Eq. 3

r – inner radius, m
P – power, W rf – friction radius, m
T – torque, N-m R – outer radius, m
f – rotation, rev/s
Old clutch – uniform wear disk clutch. The
disc condition of uniform pressure distribution is essentially
correct for new contact surfaces but not on worn clutch.
After the initial wearing-in, it is reasonable to assume that
the curve of the profile will maintain its shape, or, the
r wear thereafter may be considered to be uniform.

In order that the surfaces will remain in contact,

R the wear in the axial direction must be the same for all
values of r. But wear is proportional to the work done by
friction, which is in turn proportional to the product of the
normal pressure and the velocity of rubbing.
single disk clutch
rf = (1/2)(R + r) – Eq. 4
Torque Capacity -- All types of friction clutches
should have torque capacities of double the torque
Pressure on the Clutch
delivered to them in order to start the load from rest
without excessive slip. That is, the torque to be
The minimum pressure acts on the area
transmitted should be multiplied by a static load factor of
represented by the outer circumference multiplied by the
2 which should be increased to 3 to 4 for irregular loads.
width of the plate. The maximum pressure acts on the

1 Patrick D. Sta. Maria / July 16, 2017

 Friction Clutches Machine Design 2

area represented by the inner circumference multiplied by disengage of its own accord, the tan θ must be less than
the width of the plate. the coefficient of friction and a force must be exerted to
Pmin = F ax Pave = F ax disengage the clutch. Angle θ typically varies from 7.5° to
(2πR)(R – r) (π)(R2 – r2) 30° depending upon the type of disengagement desired
Pmax = F ax and upon the clutch facing materials. An angle of 12.5° is
(2πr)(R – r) generally considered good practice.

Fax – axial force, N b F

Pressure given for multiple disk clutch is distribu-
ted to the total area of the clutch, it is not divided by the r
number of pairs. Instead, the pressure is assumed to be
equal for each pair of disk: N
F
pressure = axial force P= F ax
R
total area (n)(π)(R2 – r2) 

As shown above, only the formula for the average
pressure applies to multiple disk clutch, the two other
N
R – r = b sin θ F = N sin θ
pressure formulas above do not. This means that even if
the problem mentioned that the clutch pressure is at max-
Normal Force
imum, only the area of an annulus (flat ring) will be consi-
N = F / sin θ N = Pav (2π)(rm b)
dered the correct area.
N= T rm = (0.5)(R + r)
Note that the total torque is the sum of the indivi-
μ rf
dual torques contributed by each pair of disks. This means
Torque Capacity
that the total axial force required by a multiple disk clutch
T = μF rf T = μN rf
is also the sum of the contributions of each pair of disks.
sin θ
Axial Forces Required
Cone Clutch To engage clutch
FE = N (sin θ – μ cos θ)
The conical friction clutch consists of the frustum To hold up cone and cup in engagement
of a cone, so fitted to a shaft by means of a feather key FH = N sin θ
that it can be pushed into an opposite engaging surface To disengage clutch
rigidly attached to the other shaft. Such clutches require FD = N (μ cos θ – sin θ)
some force to put them into gear. The inclination of the
slant side (7.5 – 30°) is highly important in order to avoid Clutch Design Considerations
"sticking" on one hand and too sudden seizure on the
other. A clutch of good design must have the ability
cup cone to withstand and dissipate heat, adequate reserve torque
capacity, and long life. For the high speeds encountered in
aircraft and automotive practice, the driven members
should have low moments of inertia and parts should be
accurately balanced. The clutch should engage smoothly
with a low operating force, have a positive release, and be
easy to repair.
spring
The coeficient of friction depends upon the facing
material and may vary with the normal pressure, tempera-
ture, cleanliness, and and wetness of the surfaces. When
Proportions may be taken as follows (see the
the contact surfaces are sliding over each other, as in
figure below) : B = 2d + 1; C = 1.5d; F = 1.8d; H = 0.5d;
starting, the coefficient is decreased. When starting, the
E = 0.4d + 0.4; G =0.3d + 0.3; t = 0.2d + 0.1; L = 2d.
inertia of the driven parts must be overcome; hence to
C t cone
provide sufficient starting capacity, some designers design
L clutches for overload capacities of 75 to 100 percent.
Often this is not desirable because slippage permits
smooth and gradual engagement; of course clutches
without overload capacity must be capable of transmitting
the desired torque after slippage has stopped. If the load
d B is variable, or subject to shock, additional service factors
often are used.
cup

G
E
H
F Problems
The equations for rf and T developed for disk
clutches apply to cone clutches with the exception that the 1. A jaw clutch for a 100 mm shaft has three jaws
pressure must be measured perpendicular to the cone with radial faces. The dimensions are: inside diameter
surface. After the clutch is engaged, and for steady of jaws, 100 mm; outside diameter, 300 mm; axial
operation, the axial force, F, required to produce the height of jaws, 50 mm; key size, 25 mm by 25 mm
normal force, N, is by 160 mm. Assume a 4 mm clearance between the
jaws and a working stress in the shaft of 42 MPa.
F = N sin θ What horsepower can be transmitted at 120 rpm?
Determine the shear and bearing stress on the jaw
The clutch may be designed for free disengage- faces.
ment, in which case the tan θ must be greater than the
coefficient of friction and a spring must be used to keep T = (π/16) d3 Ss
the cone surfaces in contact. If the clutch is not to T = (π/16)(100 mm)3 (42 MPa) T = 8246.681 N-m

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 Friction Clutches Machine Design 2

P = (2π)(8246.681 N-m)(120/60 r/s) T = nμFax rf

P = 103.63 kW / 138.97 hp Fa = T Fa = 50.930 N-m
nμrf (4)(0.1)(59.275 mm)
– mean radius Fax = 2148.039 N
rm = (1/2)(1/2)(100 + 300) rm = 100 mm P= F = 2148.039 N
– stress using force per jaw (3 jaws) A (π)(752 – 402) mm2
3F = (8246.681 N-m)/(0.1 m) F = 27.489 kN/jaw P = 169.874 kPa

Sb = 27.489 kN
(50 mm)(100 mm) Sb = 5.498 MPa 7. The large diameter and face of the disk of a multi-
Ss = (4)(27.489 kN) ple disk clutch are 250 and 25 mm, respectively.
(π)(0.302 – 0.102)m2 (1/6) Ss = 2.625 MPa The helical compression spring used to engage the
clutch has 9 1/2 effective coils of 10 mm steel wire.
The outer coil diameter is 80 mm. The free length of
2. A disk clutch consists of two steel disks in contact the spring is 185 mm. When in place with the clutch
with one asbestos-fabric-faced disk having an outside engaged, its length is 130 mm. Assuming that there
diameter of 250 mm and an inside diameter of 200 are ten pairs of friction surfaces in contact, that the
mm. Determine the horsepower that can be trans- motor runs at 1200 rpm, with the coefficient of fric-
mitted at 1000 rpm if the coefficient of friction is 0.35 tion of 0.15, determine the axial force available for
and the disks are pressed together by an axial force the clutch and the power that the clutch can trans-
of 10 kN. Assume uniform wear. mit.

rf = (1/2)(1/2)(250 + 200) mm rf = 112.50 mm – for the spring:

T = nμFarf
T = (1)(0.35)(10 kN)(112.50 mm) T = 393.75 N-m D = 80– 10 D = 70 mm
P = (2π)(393.75 N-m)(1000/60 r/s) δ = 185 – 130 δ = 55 mm
P = 41.233 kW / 55.295 hp C = D/d = 70 /10 C=7
δ = 8FC3 Na F = Gd δ
Gd 8C3 Na
3. A disk clutch having an outside diameter of 320 mm F = (80 GPa)(10 mm)(55 mm)
and an inside diameter of 120 mm is connected to an (8)(7)3 (9.5) Fax = 1687.893 N
engine which runs at 750 rpm. The coefficient of – for the clutch
friction is 0.6 while the pressure between the friction D = 250 mm R = 125 mm R – r = 25 mm
surfaces is 200 kPa. How much force is necessary to r = 125 mm – 25 mm r = 100 mm
engage the clutch? How much power is transmitted rf = (2)(1253 – 1003)
by the engine? Assume uniform pressure. (3)(1252 – 1002) rf = 112.963 mm
T = nμFax rf
T = (10 pairs)(0.15)(1687.893 N)(112.963 mm)
4. An automobile engine develops its maximum brake T = 286.004 N-m
torque at 2800 rpm when the bhp = 200. A design P = (2π)(286.004 N-m)(1200/60 r/s)
value of μ = 0.25 is expected to be reasonable for P = 35.940 kW / 48.198 hp
the asbestos facing and it is desired that the mean
diameter not exceed 200 mm and the permissible
pressure be 240 kPa. Determine the inner and outer 8. A multiple disk clutch is to transmit 20 N-m of
diameters of the single-plate clutch using uniform torque using 4 pairs of steel and bronze disks. If the
wear radius. inner diameter is restricted to 50 mm, determine the
necessary outer diameter of the disks using uniform
wear assumption and the necessary axial force. The
5. A multiple-disk clutch is to be used on machine coefficient of friction may be taken as 0.1 and the
tools. There are eight driven disks having an outside pressure is not to exceed 350 kPa.
diameter of 80 mm and an inside diameter of 60 mm.
The disks are metal and run in an oil spray. The co-
efficient of friction may be taken as 0.02 and the 9. What torque can be obtained from a cone clutch
permissible unit pressure is 700 kPa. Determine the whose minimum and maximum diameters are 500
axial force required. Determine the horsepower that and 360 mm, respectively, if the face has a width of
can be transmitted at 600 rpm. 120 mm? Use an axial force of 6 kN and a coefficient
of friction of 0.3.

6. A multiple disk clutch, steel on bronze, is to

transmit 4 kW at 750 rpm. The inner radius of con- 10. A cone clutch has a face angle of 15° with a maxi-
tact is 40 mm and the outer radius is 75 mm. The mum diameter of 600 mm and a face width of 75
clutch operates in oil with an expected coefficient of mm. The coefficient of friction is 0.2 and the permis-
friction of 0.1. Average allowable pressure is 200 kPa. sible pressure on the cone surface is 85 kPa. What
Calculate the required number of pairs of disks, the torque can be transmitted? What power may be
actual average pressure and the axial force. Assume transmitted at 800 rpm? What axial force may be
uniform pressure. exerted at this power?

T= P = 4000 W
2πf (2π)(750/60 r/s) T = 50.930 N-m 11. An engine developing 40 hp at 1250 rpm is fitted with
– capacity of each pair a cone clutch built into the flywheel. The cone has a
Fax = (Pav)(π)(R2 – r2) face angle of 12.5° and a maximum diameter of 360
Fax = (200 kPa)(π)(752 – 402) mm2 mm. The coefficient of friction is 0.2 and the normal
pressure on the clutch face is not to exceed 85 kPa.
Fax = 2528.982 N
Determine the face width required. Determine the
rf = (2)(753 – 403)
spring force required to engage this clutch.
(3)(752 – 402) rf = 59.275 mm
T = (0.1)(2528.982 N)(59.275 mm)
T = P = (40 hp)(745.7 W/hp)(60 s/min)
T = 14.991 N-m
2πf (2π)(1250 r/min)
– number of pairs
N = 50.930 N-m / 14.991 N-m N = 3.397 pairs T = 227.869 N-m
– solution 1
Use 4 pairs
– actual operating force and pressure – normal forces
N = (Pav)(2π)(rm b)

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 Friction Clutches Machine Design 2

N = FT FT = T coefficient of friction 0.3 (assume uniform wear), (d)

μ rm average pressure on the clutch.
N = T = (Pav)(2π)(rm b)
μ rm – conversion of speed and wheel revolution
b rm2 = T – Eq. 1 V = 12 km/h V = 3.333 m/s
(2π)(Pav)(μ) Nw = V = 3.333 m/s
y = (0.5 b)(sin 12.5°) y πd (π)(1.2 m) V = 0.884 m/s
y + rm = 0.18 m 12.5 1 b – wheel power
2
(0.5 b)(sin 12.5°) + rm = 0.18 m Power = force x (distance / time)
b= 0.18 – rm – Eq. 2 P = drawbar pull x velocity
(0.5)(sin 12.5°) Pw = (12.5 kN)(3.33 m/s) P = 41.663 kW
– equating 1 and 2: b = b – for the engine, revolution using gear ratio
(0.18 – rm)(rm)2 = T G = NE / NW; NE = (G)(NW)
(0.5)(sin 12.5°) (2π)(Pav)(μ) NE = (25)(0.884 r/s) NE = 22.10 r/s
(0.18 – rm)(rm)2 = (227.869 N-m)(0.5)(sin 12.5°) – engine power using efficiency, torque
(2π)(85 kPa)(0.2) PW = (PE)(eT) eT = transmission eff.
0.18 rm2 – rm3 = 230.867E–06 PE = PW/eT = 41.625 kW / 0.75 PE = 55.5 kW
rm3 – 0.18 rm2 + 230.867E–06 = 0 T= P = 55.5 kW
(solve from 0.36) rm = 172.216 mm 2πf (2π)(22.10 r/s) T = 399.688 N-m
(solve from 0) rm = – 32.928 mm – friction radius, assuming old disk
– note: zeroes of the equation using mode 5 D = d + 2w d = 320 – (2)(30) d = 240 mm
rising at –0.032928 m (–32.93 mm) rf = (0.5)(0.5)(300 mm + 240 mm) rf = 135 mm
falling at 0.040712 m (40.71 mm) F= T = 399.688 N-m
rising at 0.172216 m (172.22 mm) nμ rf (3)(0.3)(135 mm) F = 3289.613 N
– from equation 2 Note that this is force per pair of disk
b = 0.18 – 0.172216 – average pressure
(0.5)(sin 12.5°) b = 71.928 mm P= F
– normal forces (π)(R2 – r2)
N= T = 227.869 N-m P= 3289.613 N
μrm (0.2)(0.172216 m) N = 6615.791 N (π)(1502 – 1202) mm2
– also P = 129.274 kPa
N = (Pav)(2π)(rm b)
N = (85 kPa)(2π)(0.172 m)(0.072 m)
N = 6613.932 N
F = N sin 12.5°
F = (6615 N)(sin 12.5°) F = 1431.748 N

– solution 2
– face width (b) and mean radius (rm)
R = r + (b)(sin 12.5°) R = 0.18 m
r = R – (b)(sin 12.5°) – Eq. 1
rm = (1/2)(R + r)
rm = (0.5)[R + R – (b)(sin 12.5°)]
rm = R – (0.5b)(sin 12.5°) – Eq. 2
– normal forces and pressure
N = (Pav)(A); A = (2π)(rm b)
N = (Pav)(2π)(rm b) – Eq. 3
– also for normal force
N = FT FT = T b 12.5
μ rm
r R  180 mm
N= T T = μN rm
μ rm
– substituting Eq. 3 for N:
T = (μ)(2π Pav)(rm b)(rm)
– substituting Eq. 2 for rm:
T = (2πμ)(Pav b)[R – (0.5b)(sin 12.5°)]2
(b)[0.18 – 0.1082 b]2 = 227.869 N-m
(0.2)(2π)(85 kPa)
(b)[0.18 – 0.1082 b]2 = 2133.322E–06
using shift-solve b = 71.929 mm
– from equation 1:
r = 180 mm – (71.929 mm)(sin 12.5°)
r = 164.432 mm
– from equation 2:
rm = 180 mm – (0.5)(71.929 mm)(sin 12.5°)
rm = 172.216 mm
– normal force
N= T N= 227.869 N-m
μ rm (0.2)(172.216 mm)
N = 6615.616 N

12. Multiple-Disk Clutch. A vehicle with a wheel

diameter of 1.20 m is developing a drawbar pull of
12.5 kN while travelling at a speed of 12 km/h. If the
combined efficiency of the differential transmission is
75% and the overall reduction is 25:1 determine the
(a) power delivered by the engine, (b) torque
delivered by the clutch, (c) axial force in the clutch
required to transmit power if the outside diameter
and face of the clutch are 300 and 30 mm respec-
tively. There are three pairs of friction surface with a

4 Patrick D. Sta. Maria / July 16, 2017