Mechatronics in automotive engineering

Sheet (1)
Clutches
1-Derive an expression to estimate the torque transmitted by a single plate
clutch in terms of the effective mean radius, coefficient of friction, and
total axial load in cases of a) uniform pressure intensity and b) uniform
rate of wear.
2-Derive expressions for effective mean radius and torque transmitted in
case of a cone clutch due to the friction resistance between the conical
surfaces pressed together by an axial force assuming different
conditions.
3-External diameter of the clutch facing is limited to 120 mm and the inner
diameter may be assumed to be 0.3 times the external diameter. Assume
uniform wear theory. What is the effective mean radius?
4-The clutch plate has 160 mm inside and 240 mm outside diameter. The
total force provided by the springs is 5 kN, when the clutch is new. The
coefficient of friction is 0.4. What is the torque transmitted?
5-The external radius of the cone clutch is 120 mm and the internal radius
is 80 mm. The cone angle is kept at 20°. What is the effective mean
radius assuming the uniform wear theory?
6- The outer and inner diameters of a single plate clutch are 300 mm and
200 mm respectively. Both sides of the clutch are effective. The
maximum pressure intensity should not be more than 0.1 N/mm2. If
coefficient of friction is 0.3, find the power transmitted at 2500 rpm in
kW. Consider the condition of uniform wear.
7- A single plate clutch with both sides effective; is required to transmit 25
kW at 900 rpm. The outer diameter of the plate is 350 mm. the
maximum intensity of pressure over the friction surface is not to exceed
0.1 N/mm2. Considering uniform wear criteria and assuming coefficient
of friction as 0.25; determine (i) the inner diameter of the plate (ii) axial
force required to engage the clutch.
8- A cone clutch with asbestos friction lining, transmits 25 kW at 600 rpm.
The coefficient is 0.25 and the maximum intensity of pressure is 0.25 N/
mm2. The semi cone angle is 12.5o. The outer diameter of friction lining
is 250 mm. considering uniform wear theory. Determine:
i. the inner diameter of the friction lining,
ii. the face width of friction lining and
iii.the force required to engage to the clutch.
9- An automotive engine having a single plate dry friction clutch develops
maximum torque of 150 N.m. Outside diameter of the clutch plate is 1.2
times its inside diameter. Determine the dimensions of the clutch and
the axial force of the springs. The maximum allowable pressure
intensity for the clutch facings is 100 kPa and coefficient of friction is
0.3. Assume uniform wear of lining.
10- An automobile clutch has a single plate clutch of 160 mm and 240 mm
inside and outside diameters respectively. A 6 spring’s pack, used in the
clutch provides a total force of 4.8 kN, when the clutch is new and each
spring is compressed 5 mm. Maximum torque developed by the
automotive engine is 256 N.m. Determine:
i. Factor of safety of the new clutch
ii. The amount of wear of the clutch facing that will take place before
the clutch starts to slip. Assume the coefficient of friction for the
clutch face lining as 0.3.
11- Design the size of a single clutch for an automotive application that uses
an engine, which develops 38 kW at 4200 rpm. The inside diameter of
the clutch plate is to be 0.6 times its outside diameter. The clutch must
not slip even with 30% loss of engine torque due to wear of the clutch
facing. The intensity of pressure on the clutch facing is not to exceed 76
kPa. Assume coefficient of friction 0.3.
12- A car engine develops maximum torque at 15 kW and 2400 rpm. Given
the maximum allowable intensity of pressure on the friction surface =
0.7 bar. Coefficient of friction for the lining material riveted on both
sides of the clutch plate = 0.35. Inside diameter of the friction material
surface on the plate = 0.6 times the outside diameter of the friction
material. Determine the suitable size of the clutch plate friction surface
such that the clutch is capable of performing the proper function
without slip, even after a permissible loss of torque due to wear as 30%
of the engine torque.
13- A cone clutch is to be designed for an engine developing 10 kW at 1000
rpm. The width of the face may be considered 20% of the mean
diameter and the cone angle may be taken as 25 0. The maximum
allowable normal pressure between the contact faces is 80 kPa.
Determined the principal dimensions of the clutch and the axial force
required. Assume coefficient of friction 0.25.
14- A cone clutch with a semi-cone angle of 120 is to transmit 15.2 hp at 750
rpm. The width of the cone face is 0.25 of the mean diameter and the
normal pressure between contact faces is not to exceed 0.8435 kg / cm2.
 Allowing the coefficient of friction of 0.2, determined the main
dimensions of the clutch and the axial Force required.
15- An automobile clutch has a single plate of 160 mm and 240 mm, inside
and outside diameters, respectively. 6 springs pack, used in the clutch
provides a total force of 4.8 kN, when the clutch is new, and each spring
is compressed 5 mm. Maximum torque developed by the automotive
engine 256 N.m. Determine:
i- Factor of safety of the new clutch
ii-The amount of wear of the clutch facing that will take place before
the clutch starts to slip. Assume coefficient of friction for the clutch
face lining as 0.3.
16- A cone clutch is to be designed for an engine developing 10 kW at 1000
rpm. The width of the face may be considered as 20% of the mean
diameter and the cone angle may be taken as 25 deg. The maximum
allowable normal pressure between the contact faces is 80 kPa.
Determine the principal dimensions of the clutch and the axial force
required. Assume coefficient of friction μ = 0.25, and uniform wear of
clutch friction lining. The cone angle is kept at 20°. What is the effective
mean radius assuming the uniform wear theory?
17- A single plate friction clutch of both sides effective has 300 mm outer
diameter and 160 mm inner diameter. The coefficient of friction o.2 and
it runs at 1000 rpm. Find the power transmitted for uniform wear and
uniform pressure distributions cases if allowable maximum pressure is
0.08 Mpa.
18- 100 kW is transmitted at 3000 rpm by a multiple friction clutch. The
plates are immersed in oil and have friction surfaces of steel and
phosphor bronze alternately with μ = 0.07. The axial intensity of
pressure does not exceed 1.5 bar. The external radius of the friction
surfaces is 1.25 times the internal radius and the external radius is 12.5
cm. Determine the number of plates needed to transmit the required
torque. Assume uniform wear of friction surfaces.
19- A single plate friction clutch of both sides effective has 300 mm outer
diameter and 160 mm inner diameter. The coefficient of friction o.2 and
it runs at 1000 rpm. Find the power transmitted for 1-uniform rate of
wear and 2-uniform pressure distribution cases if allowable maximum
pressure is 0.08 MPa.