EMMCA3C WORKED EXAMPLES

Example 1 (Clutches)

1.1 Shown in Fig. 1 is one of the four shoes of a centrifugal

clutch. The contact surface is 160 mm in radius and the
centre of gravity of a shoe (G) is 40 mm from the contact
surface of rim. The engagement speed is 560 r/min. and µ
= 0.22.

If the clutch is to transmit 25 kW at 750 r/min, calculate:

(a) The mass of each shoe. [8]
(b) Force exerted on the beam spring by the adjusting Fig. 1. Centrifugal clutch
screw. [1]
(c) shoe
Power transmitted if the shoes are worn 1.8 mm and are not adjusted. Use spring stiffness, k = 175 kN/m. [3]

Solution:

(a) Given: inner rim diameter Di = 320 mm (Ri = 160 mm); n = 4;  = 0.22; r = 160-40 =
120 mm; engaging speed Ne = 560 r/min; running speed Nr = 750 r/min;

2𝜋×560
The engaging speed 𝜔𝑒 = 60
= 58.64 rad/s
2𝜋×750
The running speed 𝜔𝑟 = = 78.54 rad/s
60

Spring force S = mre2 = (160-40) x 10-3 x (58.64)2.m = 412.64m N … … (1)

Centrifugal force at running speed Fcr = 0.12 x (78.54)2.m = 740.22m N … … (2)

Clutch torque T = (Fcr-S)Rn = 0.22(740.22-412.64)m x 0.16 x 4 = 46.12m Nm … (3)

34000
Also, T = power/ ∴ 𝑇= 78.54
= 432.9 Nm … … … … (4)

From eq.(3) and eq.(4), 46.12m = 432.9

m = 9.39 kg.

(b) S = 412.64 x 9.39 = 3874.7 N.

(c) The new spring force S’ = 3874.7 + (170000 x 0.0016) = 4146.7 N

New torque T’ = 0.22(740.22x9.39-4146.7) x 0.160 x 4 = 394.8 Nm

Reduced power P’ = 394.8 x 78.54 = 31.01 kW.

1.2 The following data refers to a soft surface cone clutch: larger diameter: 300 mm; cone angle: 15o; face width: 60
mm. The clutch is required to transmit a torque of 250 Nm at a speed of 1500 r/min. The coefficient of friction,
µ = 0.25.
(a) Assuming uniform rate of wear theory, determine:
 (i) The axial force required to transmit the torque. [7]
(ii) The axial force to engage the clutch. [2]
(iii) The average normal pressure on the contact surfaces when maximum torque is being transmitted. [2]
(iv) The maximum normal pressure. [2]
(b) Consider the same clutch but assume uniform pressure, determine the axial force to transmit the given torque.
[3]

Solution:
(a) Given: b = 60 mm; θ = 7.5o; Ro = 150 mm; T = 250 Nm; N = 1500 r/min.; µ = 0.25
𝑥
From the figure, 𝑏
= 𝑠𝑖𝑛 𝜃 ⟹ 𝑥 = 60 𝑠𝑖𝑛 7.5𝑜 = 7.068 𝑚𝑚 b
x
𝑅𝑖 = 160 − 7.068 = 152.93 𝑚𝑚
160+152.93 Ro
𝑅𝑚 = 2
= 156.47 𝑚𝑚

𝜇𝐹𝑅𝑚 𝑇 𝑠𝑖𝑛 𝜃 215×𝑠𝑖𝑛 7

(i) 𝑇= 𝑠𝑖𝑛 𝜃
⟹ 𝐹= 𝜇𝑅𝑚
= 0.25×0.15647
= 669.8 𝑁

(ii) 𝐹𝑒 = 𝐹(1 + 𝑐𝑜𝑡 7) = 669.8 × 3.036 = 2033.6 𝑁

𝐹 669.8
(iii) 𝑃𝑎𝑣. =
𝜋(𝑅𝑜2−𝑅𝑖2)
=
𝜋(0.1602 −0.152932 )
= 93.37 kPa

𝐹 669.8
(iv) 𝑃𝑚𝑎𝑥. = 2𝜋(𝑅 = = 98.6 kPa.
𝑜 −𝑅𝑖 )𝑅𝑖 2𝜋(0.160−0.15293)0.15293

(b) Assuming uniform pressure theory;

𝜇𝐹 2 𝑅3 𝑅3 0.25𝐹 2 0.1603 −0.152933

𝑇 = 𝑠𝑖𝑛 𝜃 [3 (𝑅0− 𝑖
2 𝑅 2 )] = [ (
𝑠𝑖𝑛 7 3 0.1602−0.152932
)] ⟹ 215 = 0.321𝐹
0− 𝑖

∴ 𝐹 = 669.78 𝑁

Example 2 (Brakes) 450

2.1 Fig. 2 shows a band brake with a 450 mm diameter brake drum.
The maximum pressure between the band and the drum is 480
kPa. The coefficient of friction,  = 0.27 and band width is 110
mm. Other dimensions are as shown in the figure. P
(a) Determine the band tensions and the actuating force for
clockwise rotation. [12] A D
(b) What actuating force will be necessary if this brake were C
used with counter-clockwise rotation? [8]
B
520

Solution: Fig. 2: Band

Dimensions in mm
𝑇1 brake
(a) 𝑃𝑚𝑎𝑥. = 𝑊𝑅 ; where W = 110 mm; R = 225 mm
hence, T1 = 480 x 103 x 0.11 x 0.225

T1 = 11880 N

Self-locking occurs when;

247
100
25
≤ 𝑒 𝜇𝜃 , where, 𝑒 𝜇𝜃 = 𝑒 0.27×57.3 = 𝑒1.164 = 3.203
 100
Since = 4 > 3.203, it implies the brake is not self-locking.
25

𝑇1
∴ 𝑇2
= 𝑒 𝜇𝜃 = 3.203 … … … (1)

MA = 0:
T1 x 0.025 + P x 0.52 = T2 x 0.1

𝑇1 11880
But T1 = 11880 N, = 3.203; ⇒ 𝑇2 = = 3709 N
𝑇2 3.203

0.52P + 11880 x 0.025 = 3709 x 0.1

P = 142.12 N

(b) For anti-clockwise rotation, the brake is not self locking.

T1 = 11880 N, T2 = 3709 N
MA = 0:
P x 0.52 + 3709 x 0.025 = 11880 x 0.1
P
0.52P = 905.79 T1
P = 2106.3 T2

2.2 Fig. 3 shows a two-shoe internal-expanding brake. The following data

is given for this type of brake: brake drum diameter = 280 mm; shoe
face width = 30 mm; µ = 0.26; max allowable pressure = 1.2 MPa; θ1 =
0, θ2= 120o; θm = 90o; dimension c = 200 mm; drum centre to pivot
centre (dimension a) = 115 mm. The right shoe is self-energising and
will have a higher pressure than the left shoe. Both shoes are
symmetrical.
Determine:
(a) The actuating force. [6]
(b) The brake capacity. [5]
(c) The percentage of the total braking force contributed by the left
shoe. [3]

Solution: Fig.3. Internal expanding brake

𝑀𝑐 −𝑀𝑓
(a) For the right shoe, actuating force 𝐹= 𝑐

The moments of the frictional forces,

𝜇𝑝𝑚×𝑏×𝑟 𝜃 𝜇𝑝𝑚 ×𝑏×𝑟 𝑎

𝑀𝑓 = 𝑠𝑖𝑛 𝜃𝑚
∫𝜃12 𝑠𝑖𝑛 𝜃(𝑟 − 𝑎. 𝑐𝑜𝑠 𝜃) 𝑑𝜃 = 𝑠𝑖𝑛 𝜃𝑚
× [𝑟 − 𝑟. 𝑐𝑜𝑠 𝜃2 − 2 𝑠𝑖𝑛2 𝜃2 ]

0.26×1.2×106 ×0.03×0.14 0.115

𝑀𝑓 = [0.14 − 0.14 𝑐𝑜𝑠 120𝑜 − 𝑠𝑖𝑛2 120𝑜 ] = 218.7 Nm
𝑠𝑖𝑛 90𝑜 2

The moments of the normal forces,

 𝑝𝑚 ×𝑏×𝑟×𝑎 𝜃 𝑝𝑚 ×𝑏×𝑟×𝑎 𝜃2
𝑀𝑛 = 𝑠𝑖𝑛 𝜃𝑚
∫𝜃12 𝑠𝑖𝑛2 𝜃 𝑑𝜃 = 𝑠𝑖𝑛 𝜃𝑚
[
2
− 0.25 𝑠𝑖𝑛 2𝜃2 ]
1.2×106×0.03×0.14×0.115 120
𝑀𝑛 = 𝑠𝑖𝑛 90𝑜
[
2×57.3
− 0.25 𝑠𝑖𝑛(2 × 120𝑜 )] = 732.4 Nm

732.4−218.7 2
Then, 𝐹 = 0.2
= 2568.5 N

(b) For the left shoe,

𝑀𝑛1 +𝑀𝑓1 𝑝1 𝑝1
𝐹= 𝑐
, where 𝑀𝑛1 = 𝑀𝑛 𝑝𝑚 and 𝑀𝑓1 = 𝑀𝑓 𝑝𝑚
𝑚 𝑚

1 𝐹×𝑝𝑚 ×𝑐 2568.5×1.2×106×0.2
𝑝𝑚 = = = 648.13 kPa
𝑀𝑛 +𝑀𝑓 732.4+218.7

Torque capacity,
1 )𝑏𝑟 2 [
𝑐𝑜𝑠 𝜃1 − 𝑐𝑜𝑠 𝜃2 1 − 𝑐𝑜𝑠 120𝑜
𝑇 = 𝜇(𝑝𝑚 + 𝑝𝑚 ] = 0.26 × (1.2 × 106 + 648.13 × 103 ) × 0.03 × 0.142 [ ]
𝑠𝑖𝑛 𝜃𝑚 𝑠𝑖𝑛 90𝑜
T = 423.8 Nm.

(c) Contribution of left shoe = 648.13/(648.13+1200) x 100% = 35.07%.