Chapter 4

Design of clutches
 CLUTCHES
A clutch is a mechanism used for repeated connection and
disconnection of a torsional load from the driving power. A clutch
is designed to transmit a certain maximum torque, hence its
horsepower/kilowatt rating depends on rpm. A number of clutches
have been designed in the past: Positive contact clutches transmit
power due to direct contact, friction clutches (which are the most
widely used clutches) transmit by frictional forces, magnetic
clutches by magnetic forces, and fluid clutches by the direct action
of hydrodynamic forces.

Overrunning clutches are also called one-way clutches, so as to

transmit torque only when the speed of the driven element is lower
than that of the driver element.
Clutches can be actuated by direct mechanical, hydraulic,
pneumatic or electrical ways.
The principle of operation of
frictional clutches and couplings
are similar. Therefore, in many
applications, they are integrated.

A brake can be regarded as a

coupling where the velocity of the
driven element is equal to zero.
Types of friction clutches and brakes
Classification of clutches
Positive contact clutches
 Simple two-element disk clutch

The torque capacity T of a simple two-element disk clutch can be found from the
integration of the moment of the friction force over the surface of the clutch:
Ro Ro

T   Ff r dA  p f  rdA  pf  2r  r  dr  2pf  r 2  dr

A A Ri Ri

where p is the disk pressure (assumed to be constant over the surface of the disk), f
is the coefficient of friction, Ri and Ro the internal and external radii, respectively.

Ro3  Ri3
T  2 p f
3
Axial force required to create the disk pressure p:

F   p  dA  2 p  r  dr   pRo2  Ri2 
Ro

A Ri

Hence, the average disk pressure created by the axial force F:

F
p
 Ro2  Ri2 

Substituting for the p in the torque relation,

Ro3  Ri3 F f R 3
 R 3

T  2 p f 2  o2
3 Ro  Ri2 
i

 2  Ro3  Ri3 
T  F  f   2   F  f  Rf
2 
 3  Ro  Ri 
 The term Rf is called “Frictional radius”:

2  Ro  Ri 
3 3

Rf   2
3  Ro  Ri2 

Multiple disk clutches

In order to increase the torque carrying capacity of a clutch, a multiple number of disks
are placed on the driving and driven shafts. The disk surfaces are often alternating
materials- bronze and steel.
 The number of disk pairs:

N = nbronze + nsteel-1
A multiple disk clutch with N pairs of disks shall have the torque carrying capacity
of:
T  F  f  Rf  N

An oil-actuated multiple disk clutch

Simple disk clutch
A multi-disk clutch

An automobile clutch
Example
A single disk clutch is actuated by an axial force of 4500 N, and has an inner disk radius
of 50 mm, outer disk radius of 100 mm. Find the torque capacity of the disk if the
coefficient of friction is 0.10.
F = 4500 N
Ri = 0.05 m
Ro = 0.10 m
f = 0.10

2  Ro  Ri  2 0.103  0.053
3 3

Rf   2 2 
   0.0778 m
3  Ro  Ri  3 0.10  0.05
2 2

T =F. f . Rf = 4500 N  0.10  0.0778 m = 35.01 N.m

Example
A multiple disk clutch is to transmit 3.7 kW of power with 750 rpm. The disks have an
inner disk radius of 38 mm, outer disk radius of 70 mm. The coefficient of friction is
0.10. Maximum brake pressure is 3.4 bar.
a. What is the number of disks required ?
b. What shall be the average pressure ?
c. What is the axial force required ?
P = 3.7 kW, 750 rpm
Ri = 0.038 m Ro = 0.07 m.
f = 0.10
Pmax = 3.4 bar = 340 kPa
P P 30P
Torque transmitted : Ttr     47.11 N .m
 2 rpm / 60   rpm

Torque carrying capacity of a single disk pair : T1 = F f Rf

F =p  (R02 – Ri2) = 340 103 N/m2    (0.0702 – 0.0382 ) =3691.5 N (per disk)
 2  Ro  Ri  2 0.07 3  0.0383
3 3

Rf   2 2 
   0.0556 m
3  Ro  Ri  3 0.07  0.038
2 2

T1-disk = F f Rf =3691.5  0.10  0.0556 = 20.52 N.m

Number of disk pairs : N = Tt / T1-disk = 47.11 / 20.52 = 2.295

Use 3 pairs of disks  (a)

Approximate force: T = F f Rf . N  Axial force: F=T/(F f Rf . N )

= 7474 N  (c)
For uniform wear A= ½(Ro + Ri)

Average pressure: p = F/A =F/[ (Ro2 – Ri2)] =7474/[(0.072 – 0.0382)]

= 688731N/m2 = 6,887 Bar  (b)
 Conical clutches
Conical clutches use the wedge effect to increase the normal and hence
frictional force between the two surfaces.

The differential area dA between the radii r and r+dr :

 dr 
dA  2 r  
 sin 

Torque conveyed:
2 r
Ro

T   dT   p  f  r dA   p  f  r  dr
dA Ri sin

2 p f 2 2 p f 3
Ro  Ri3 
Ro

 
sin R
r dr 
3 sin
i
Normal force on the friction surface: Fn =p 2 Rm b
Circumferential differential area: dS Rm b d

Normal differential force acting on this area: dN = p dS =p Rm b d

Horizontal component: dF = dN sin (the useful component)

2

F   dF  p Rm b sin  d  2 p Rm b sin
0

F
F  Fn sin or Fn 
sin
Torque transmitted:
2 p f 3
T
3 sin 

Ro  Ri3 
Fn  f Ro3  Ri3
 
Rmb sin  3

F f  2  Ro3  Ri3 
b sin=Ro – Ri ; Rm = ½ (Ro + Ri)  T   2 
2 
sin   3  Ro  Ri 
 Assuming that no other forces are developed during the engagement, the forces on the
clutch surface can be analyzed as:

Force required for engagement :

Fe = Fn sin  + Ff cos
= Fn sin  +(f Fn) cos
Fe = Fn (sin  + f cos)

Force required for retainment (of the clutch in the engaged position): Fret = Fn sin 

Force required for disengagement :

Fde = f Fn cos - Fn sin = Fn (f cos - sin)

Example
Compare the power transmission capacities of two clutches- A conical clutch and a multi-disk
clutch having the same mean radius and same axial force. Coefficient of friction is the same
for both clutches. Multi-disk clutch has four steel and three bronze disks. Clutch angle is 10
degrees in the conical clutch.
  2  Ro3  Ri3 
For a multi-disk clutch : Tmdc  F  f  N   2 
2 
 3  Ro  Ri 
Fn f  2  Ro3  Ri3 
For a conical clutch: Tconic    2 
2 
sin  3  Ro  Ri 

N = nbronze + nsteel-1 = 4+ 3 – 1 = 6

For the same Ro and Ri,

Tmdc N
  N sin  6 sin10 o  1.042
Tconic 1
sin
Example
A conical clutch whose internal surface is asbestos-lined is to transmit a torque
of 100 N.m. If an axial engagement force of 900 kN is applied, estimate the
required length (b) of the conical disk. Conical angle ( ) is 12o, maximum
average pressure (p) is 1.1 bar and coefficient of friction (f) is 0.20.
 Force required for engagement: Fe = Fn (sin  + f cos)

900 =Fn (sin 12o + 0.20cos12o)  Fn = 2230 N

F f  2  Ro3  Ri3 
Tconic    2   Fn f Req
2 
sin   3  Ro  Ri 
T 100 N .m
Req  conic   0.224 m
Fn f 2230N  0.20


Fn  p 2 Reqb   b
Fn

2230 N
2 p Req 2  1.1 10 N / m  0.224 m
5 2
 0.0144 m

b= 15 mm is selected.
A manually operated clutch (widely used in small marine craft)
Clutches can also have their friction surfaces on the outer rim, where the engagement
can be hydraulic, pneumatic, electrical or centrifugal force-actuated.

Pneumatic clutch
 A centrifugal-acting rim clutch

A centrifugal clutch mechanism

• Example: Plate clutch having a single driving plate with two contact
surfaces on each side is required to transmit 110 kW at 1250 r.p.m. The
outer diameter of the contact surfaces is to be 300 mm. The coefficient of
friction is 0.4. a. Assuming a uniform pressure of 0.17 N/mm2 ; determine
the inner diameter of the friction surfaces.

Ro3  Ri3
T  2 p f
3