16.

Clutches and Brakes

Introduction

Objectives

Recognize the basic geometries of clutch and brake

systems.

Calculate the frictional forces and torque capabilities

in brake systems.

Understand the principles of heat generation and

heat removal from brake systems.

Calculate frictional brake horsepower and recognize

how to use it.

Clutch is a device that connects and disconnects

two collinear shafts.

Purpose of a brake is to stop the rotation of a

shaft.
Braking action is produced by friction as a
stationary part bears on a moving part.

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Similar to couplings
Friction and hence heat dissipation

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Heat dissipation is a problem

Brake fade during continuous application of braking
due to heat generated

Plate clutch

Uses

Cone clutch

Spring loaded flat surfaces

power in either direction

Uses

Transmit

Easy
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tapered friction surfaces

to engage

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Caliper disc brake

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Drum brake

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Block brake Wagon brake

Drum brake

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Fig. 1616-7 Disc brake

Band brake

Belt

wrapped around the wheel

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11

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Friction Materials

Asbestos fibers embedded in an epoxyepoxy-type material

Good thermal properties

High friction coefficient (0.35 to 0.50)
Environmental concerns

Polymer compounds with impregnated material

Metal shavings
Graphite
Sintered iron

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Torque and Forces

Plate type clutch

Sliding friction
Friction force, Ff = f N
f = coefficient of friction
N = normal force

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Plate type clutch

Rotating torque, Tf =
Ro = outside radius
Ri = inside radius

R + Ri
f N o

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14

Example Problem 16-1: Torques and Forces on

Clutches and Brakes

Friction power can be calculated as,

A plate-type clutch has the following properties:

Ro = 12 in

Ri = 9 in

Tf n
63,000

Pf =

engagement force of 120 lb (normal force)

turns at 2000 rpm
Friction disc has coefficient of friction of .3.
Determine torque and power that can be transmitted by this system.

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Example Problem 16-1: Torques and Forces on

Clutches and Brakes (contd.)

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Example Problem 16-2: Torques and Forces on

Clutches and Brakes

Torque capacity:
(16-2)

Tf = f N

( ro + ri )
2

For the short-shoe drum brake

shown, determine the braking
torque for the following dimensions:

12 in + 9 in
Tf = .3 (120 lb)

a = 4 in
Tf = 378 in-lb

L = 20 in
Power:

D = 12 in

(16-3)

Pf =

Pf =

Tf n
63,000

f = .4
W = 100 lb:

378 (2000)
63,000

Pf = 12 hp

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Cone clutch

Example Problem 16-2: Torques and Forces on

Clutches and Brakes (contd.)

Find moments to determine normal force:

Mp = WL a N

Mp = 100 lb 20 in 4 in N
N = 500 lb

Torque friction:
Tf = f N

D
2

Tf = .4 (500 lb)

12 in
2

Tf = 1200 in-lb

This analysis assumes the lever arms stay approximately horizontal.

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This becomes a bit complicated because of

the cone angle
In this case the frictional force is given by
Tf = Ff rm= f N rm
Fa
Normal force, N = sin + f cos
Fa = axial force
= cone angle
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Cone clutch

Fig. 16.8 Cone clutch geometry

Combining the above two equations we get

Tf =

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Example Problem 16-3: Torques and Forces on

Clutches and Brakes

f rm Fa
sin + f cos

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Example Problem 16-3: Torques and Forces on

Clutches and Brakes (contd.)
(16-5)

Tf =

For the cone clutch shown,

determine the torquetransmitting capacity based on
the following parameters:

Tf =

12 in
.35
75 lb
2
sin 20 + .35 cos 20
Tf = 235 in-lb

Dmean = 12 inches

For = 10:

Fa = 75 lb
f = .35

Tf =

= 20

12 in
.35
75 lb
2
sin 10 + .35 cos 10

Tf = 304 in-lb

Also solve if = 10 and

compare the results.

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f rm Fa
sin + f cos

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The smaller angle creates a greater wedging force and, correspondingly,

larger torque capacity.

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Example Problem 16-4: Torques and Forces on

Clutches and Brakes

Example Problem 16-4: Torques and Forces on

Clutches and Brakes
First, find the rate of deceleration. Converting 60 mph to ft/sec:

truck has total weight of 40,000 lb and is

traveling 60 mph.

60 mph

The brake design calls for it to be able to stop in

400 feet.

5280 ft
hr
= 88 ft/sec
mile 3600 sec

Determine stopping force required.

Determine stopping torque required if wheels are
36 inches in diameter.
Determine torque per brake, assuming there are
10 sets of brakes.
Assuming each brake is a disc brake with mean
radius of 10 inches, determine normal brake force if25
f = .4.

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Example Problem 16-4: Torques and Forces on

Clutches and Brakes (contd.)

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Example Problem 16-4: Torques and Forces on

Clutches and Brakes (contd.)

Find the stopping rate:

Find the torque, if the wheels are 36 inches in diameter:

D = Va t

T = Fr
D
t =
Va

T = 12,100 lb
t =

400 ft
88
ft/sec
2

T = 217,800 in-lb
For each wheel:

t = 9 sec

T = 21,780 in-lb

V = at
a =

a =

Braking normal force:

V
t

(16-2)

Tf = f N rm

88 ft/sec
9 sec

Tf
N =
f rm

a = 9.8 ft/sec2

Find the stopping force:

F =

36 in
2

N =

W
a
g

21,780 in-lb
.4 10 in

N = 5,450 lb
F =

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40,000 lb
9.8 ft/sec2
32.2 ft/sec2
F = 12,100 lb

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Rotational Inertia and Brake Power

Inertia and frictional horsepower

Energy from rotating torque
Uf = F D Nt = Tf 2 Nt
Uf = Frictional work
D = effective diameter
Nt = number of turns

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Rotational Inertia and Brake Power

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This is a significant normal force, especially for a disc brake system.

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Power associated with stopping

T n
Uf
Pf = f
=
63,000 550 t
Tf inin-lb
n rpm
t seconds

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Heat generated

Energy absorbed can be the potential energy or

the kinetic energy
Potential energy, PE = W (h1 h2)

Temperature rise is

c = specific heat

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Example Problem 16-5: Rotational Inertia

and Brake Power

Uf
Wm c

= 101 ftft-lb/lb/
lb/lb/F for cast iron
= 93 ftft-lb/lb/
lb/lb/F for steel
= 15 ftft-lb/lb/
lb/lb/F for aluminum

W
(V12 V22 )
Potential energy, KE =
2g

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T =

Wm = weight of brake system that can absorb

the heat

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Example Problem 16-5: Rotational Inertia

and Brake Power
Converting 50 mph to ft/sec:

3500-pound automobile is traveling 50 mph

and decelerates on flat ground at a rate of
20 ft/sec2.

50 mph

hr
5280 ft
= 73 ft/sec
3600 sec mile

Kinetic energy to be absorbed:

Each of the four steel brake drums weighs

10 pounds.

KE =

KE =

Assuming all heat is absorbed by the

drums during this period, find energy
absorbed, average frictional power, and
temperature rise of drums.
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3500 lb (73 ft)2

2(32.2 ft/sec2) sec2

KE = 289,620 ft-lb
(Energy gain U = KE lost.)

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Example Problem 16-5: Rotational Inertia

and Brake Power (contd.)
Uf = W c T

(16-9)

WV2
2g

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Example Problem 16-5: Rotational Inertia

and Brake Power (contd.)

(16-12)

Frictional power could then be found:

Uf

T = W c

(16-7)

289,620 ft-lb
T =
ft-lb
40 lb 93
lbF

f hp =

Uf
KE
=
550 t
550 t

fhp =

T = 78
Finding the stopping time:

289,620
550 (3.7)

f hp = 142
V = a t
t =

t =

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V
a

73 ft/sec
20 ft/sec2

t = 3.7 sec

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Automotive brake

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