CLUTCHES AND BRAKES

Ø Clutch is a coupling that permits the smooth connection and disconnection of two
shafts during rotation, at the operator's will.
Ø Clutches are indispensable where frequent starts, stops, changes in mode of
operation, and reversal of direction are required, as in the case of vehicles,
machine tools, and similar equipments.

TYPES OF CLUTCHES:

Clutches can be classified based on the control method as

(a) Mechanical,
(b) Pneumatic and hydraulic
(c) Electrical.
They can also be classified, based on the coupling methods by which the clutch element
are engaged as,
(a) Positive contact,
(b) Friction,
(c) Overrunning,
(d) Magnetic
(e) Fluid coupling.

Plate or Disc Clutches :

Ø In a plate clutch the torque is transmitted by friction between one or more pairs of
co-axial annular plates maintained in contact by an axial thrust.
Ø Both faces of each plate are normally effective so that a single plate-clutch has
two pairs of surfaces in contact. A car clutch consists of a single plate effective on
both sides. Figure shows the simplified form of a single- plate clutch. The plates
shown as S are usually steel and are inserted on the splines of shaft C to permit
axial movement (except for the last disc).
Ø The plates shown as B are usually bronze and are inserted in the splines of
member D.
Multiple Disc Clutch :

Ø Higher torque capacity can be obtained by means of multiple disc clutches.

Ø The plates shown as S are usually steel and are inserted on the splines of shaft C
to permit axial movement (except for the last disc).
Ø The plates shown as B are usually bronze and are inserted in the splines of
member D.

Friction Materials for Clutches :

Ø A friction material suitable for clutches should provide a high coefficient of

friction, resist seizing of the mating surfaces and have a low wear rate to
guarantee a long life.
Ø When a clutch operates "dry", coefficient of friction is high and the torque
capacity is high.
Ø However, the absence of a lubriciant makes heat dissipation, more difficult.
 Ø When a clutch operates "wet",coefficient of friction and hence torque capacity are
low. Since the coefficient of friction is reduced, there is a need for larger actuating
force, more clutch plates or larger clutch plates to provide an adequate torque
capacity.
Ø These disadvantages are offset Shifting groove by the reduced wear and increased
heat dissipation.

Cone Clutches :

Ø Cone clutches were extensively used in automobiles.

Ø Recently they have been replaced by disc clutches, except in synchronizing device
in automobile transmission.
Ø The smaller the semi-cone angle, a, the lower is the clamping force required.
Problem 2

A leather faced conical clutch has cone angle of 30°. The pressure between the contact
surfaces is limited to 0.35N/mm and the breadth of the conical surface is not to exceed 1/3
of the mean radius. Find the dimensions of the contact surfaces to transmit 22kWat
2000rpm. Also calculate the force required to engage the clutch.. Take coefficient of
friction as 0.15.
Problem 3

A single plate clutch, both sides being effective, is required to connect a machine shaft to
a driver shaft which runs at 500 rpm. The moment of inertia of the rotating parts of the
machine is 1 kgm2. The inner and outer radii of the friction discs are 50 mm and 100 mm
respectively. Assuming uniform pressure of 0.1 N/mm2 and coefficient of friction of 0.25,
determine the time taken for the machine to reach full speed when the clutch is suddenly
engaged. Also determine the power transmitted by the clutch, the energy dissipated
during engagement.
 BRAKES

Ø Brake is a device which is used to bring to rest or slow down a moving body. Safe
operation of vehicles demands dependable brakes.
Ø Brake is required to absorb the kinetic energy of the moving parts or the potential
energy of the objects being lowered by hoist when the rate of descent is
controlled.
Ø The absorbed energy is dissipated in the form of heat.

CLASSIFICATION OF BRAKES:

(a) Caliper disc brake,

(b) Block brake,
(c) Band brake,
(d) Block and band Brake and
(e) external and internal shoe brakes.

Caliper Disc Brake :

Ø This brake is capable of a high torque capacity in a small space and can be easily
controlled. The heat can be dissipated rapidly.
Ø Mechanical fade (reduction in friction coefficient at elevated temperature) is
absent.
Ø For the above reasons disc brakes find widespread use in front axles of passenger
cars and motor cycles.
Ø Bicycle brakes are the best known examples in which the wheel rim constitutes
the disc.
Ø Friction lining on the pads contacts only a small portion of the disc surface
leaving the remainder exposed to dissipate heat.
Ø In the case of drum brakes the heat dissipation area is in such small as shoes
(friction lining) contact the drum over a large area.
Heat Dissipation in Brakes :

A brake absorbs energy (kinetic and potential) and dissipates the resulting heat without
developing high temperatures that destroy (burn) brake itself.
Heat dissipation capacity can be increased by
(a) increasing the exposed surface areas by providing fins,
(b) increasing the air flaw past these surfaces, by increasing the air pumping action of the
rotating parts and by removing air flaw restrictions and
(c) increasing the mass and specific heat of parts that are in immediate contact with
friction surfaces so. That heat star age capacity is increased.

Braking Capacity :

Ø It depends upon unit pressure between the braking surfaces, the coefficient of
friction and ability to.
Ø Dissipate heat equivalent to the energy being absorbed.
Brake Lining Materials:

(a) Should have high coefficient of friction

(b) should retain braking capacity at temperatures up to 300°C; should have resistance to.
(c) should have high heat conductivity.

Construction Details of Block Brake:

Ø External shoe or block brakes consist of shoes or blacks pressed against the
surface of the rotating cylinder called brake drum.
Ø The black may be rigidly mounted to a pivot lever. Block (shoe) is made of cast
iron provided with brake lining which may be secured with rivets or countersink
screws.
Ø Brake lever is of forged or cast steel
Ø Brake drum is of cast iron. Width of the drum should be 5 to 10 mm greater than
the width of the shoe.
Ø If pivot Q is located at the intersection of the resultants of the normal and
frictional forces acting on the shoe there is no tendency of the shoe to rotate about
pivot, so that the wear is equalized.
Ø As wear occurs, the pivot moves progressively closer to the drum.
Ø This, increases the tendency of the shoe to rotate about Q and hence rapid wear
occurs on either the toe of the shoe (edge farthest from pivot 0) or heel (edge
nearest to pivot 0).
Questions:

1. Explain the types of clutches.

2. Explain the types of brakes.
3. Explain Disc Clutches.
4. Explain Multiple Plate clutches.
5. Explain Heat dissipation in brakes.

6. Calculate the average bearing pressure and the initial and average braking powers
for the block shoe .The diameter of the drum is 400mm and it rotates at 200 rpm.
Coefficient of friction is 0.2 and drum width is 75 mm.