Clutch Design

Dr. Yehia Eldrainy

Clutch introduction
• a device to provide a coupling
from the engine crankshaft to
the transmission.
• This allows the engine to be
started and run without the
vehicle moving and the vehicle
to be started from rest under
control at various rates of
acceleration.
• On manual gearboxes, the drive
from the engine also has to be
disconnected during gear
changes.

Diagram of a conventional single plate clutch

 Clutch introduction
• The spring pressure clamps the pressure
plate onto the driven plate and the
flywheel.
• When the driver depresses the clutch
pedal the movement is passed to the
release bearing by either hydraulics or
cable and the release bearing then pushes
or pulls the diaphragm spring (depending
on whether the clutch is a ‘push’ or ‘pull’
design

Diagram of clutch when released

 Clutch introduction
• By depressing the diaphragm spring
the pressure on the driven plate is
released.
• This actuation of the spring is achieved
by hydraulics, cable or on older
vehicles may have been a mechanical
linkage.
• When the load on the cover plate is
released the driven plate is allowed to
rotate freely inside the assembly and
the drive to the transmission is
disconnected.
Types Of Clutch
Types Of Clutch
Friction Clutches:
• Friction Clutches work on the basis of the frictional forces developed between the two or more
surfaces in contact.
• Friction clutches are usually – over the jaw clutches due to:
• their better performance.
• There is a slip in friction clutch.
• Their merits are
• They friction surfaces can slip during engagement which
enables the driver to pickup and accelerate the load with
minimum shock.
• They can be used at high engagement speeds since they
do not have jaw or teeth
• Smooth engagement due to the gradual increase in
normal force.
• The major types of friction clutches are:
• Plate clutch (Single plate and multiple plate)
• Cone clutch
• Centrifugal clutch
Single Plate clutch
 Design of clutch plate
• W=total axial load
• R1=External radius of clutch plate
• R2=internal radius of the clutch
plate
• P=intensity of pressure between
contacting surfaces.
• μ=coefficient of friction between
contacting surfaces
• Consider a elemental ring of radius
‘r’ and thickness δr on the
contacting surface.
• therefore, δA = 2π r δr
• Area of the ring on contacting
surface is, δW= p 2π r δr
• Axial load on the ring is, δW =
pressure× Area of the ring
Design of clutch plate
• Frictional resistance offered by ring is,
F = μ δW r
F = μ(p 2π r δr) 2π μ p r δr

• Frictional torque acting on the ring is,

T = Fr r

T = 2π μ p r δr.r = 2π μ p r2 δr
• Torque transmitted by single plate clutch is
obtained by considering following two
assumptions:
a. uniform pressure theory
b. uniform wear theory
Design of clutch plate
(a)uniform pressure theory:
• Assuming that the intensity of pressure over the entire contacting surface area is constant,
• Then, p=constant
𝑙𝑜𝑎𝑑 𝑤
• 𝑃= = 2 2
𝑐𝑜𝑛𝑡𝑎𝑐𝑡 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑎𝑟𝑒𝑎 𝜋(𝑅1 −𝑅2 )

• Total torque transmitted by single plate clutch can be obtain by integrating Equation
Design of clutch plate
[∵p=Constant]

Equation (A) gives the torque transmitted by single plate clutch due to friction considering
uniform pressure theory.

𝑇 = 𝜇𝑊𝑅

Where 𝑅 = is called the equivalent radius.

Design of clutch plate
(b) Uniform Wear Theory
• In this theory, we are considering that wear which take place is uniform over the entire
contacting surface i.e. P.r=constant P.r=C
P=C/r
• Axial load acting on the ring is:

δW = p 2π r δr
𝐶
δW = 2π r δr
𝑟
δW = 2π C δr
• Integrating above Equation within limit we get
W = 2π C (R1 - R2)

• We know that frictional torque acting on ring is,

Design of clutch plate

• Torque transmitted by single plate clutch can be obtain by integrating the previous Equation within
the limit R2 to R1 we get,

• This is the torque transmitted by single plate due to friction considering uniform wear theory.

• Where 𝑅 = is called is the mean radius or the equivalent radius.

Design of clutch plate
• Power transmitted by single plate clutch is given by,

• where, N Speed of shaft in rpm

• Assume uniform pressure conditions for new clutch and uniform wear conditions for an old clutch.

• Under uniform wear conditions pressure is maximum at the inner radius and minimum at the outer
radius.
Multi plate clutch
 It consists of two sets of plates the driving plates and driven plates arranged
alternately, driving shaft, spring, splined driven shaft etc.
 Multiplate Clutch
• Multiplate clutch is used when large torque is to be transmitted e.g. motor cars and machine tools
• Multiplate clutch is used when compact construction is required e.g. scooters and motor cycles

• 𝑇 = 𝑛 𝜇 𝑊𝑅, for a single clutch n = 2.

• A multi plate clutch may be used when
large torque is to be transmitted.
• The inside discs (n1) are of steel are
connected to the driven shaft.
• The outside discs (n2) are of bronze are
held by bolts and are fastened to the
housing which is keyed to the driving
shafts.
• The total number of active friction
surfaces is 𝑛 = 𝑛1 + 𝑛2
Cone clutch
• It consists of driving shaft, splined driven shaft, outer
cone (cup), inner cone (cone), helical compression
spring etc. The outer cone (cup) is keyed to the
driving shaft and inner cone is free to slide axially on
the splined driven shaft.

• To engage the clutch axial force is provided by a

helical compression spring. Clutch is disengaged by
means of fork fitted in shifting collar or groove on
the outer surface of cone, leather, cork or asbestos is
used as friction lining.
Cone clutch
Centrifugal clutch
• It is works on the principle of centrifugal force.
Centrifugal force is increases with the increase in
speed.
• It consists of spider having radial guide, sliding shoes,
helical tension springs co-axial drum
• The spider having four equally spaced radial guides is
keyed to the driving shaft. Sliding shoes can slide
radially in guides.
• The sliding shoes are covered with frictional material
from outer side. These shoes are held against spider
on driving shaft by helical tension springs and all
these assembly is enclosed in coaxial drum which is
mounted on driven shaft.
Centrifugal clutch
Clutch Material
 Clutch Materials
The material used for lining of friction surfaces of a clutch should have the following characteristics :
1. It should have a high and uniform coefficient of friction.
2. It should not be affected by moisture and oil.
3. It should have the ability to withstand high temperatures caused by slippage.
4. It should have high heat conductivity.
5. It should have high resistance to wear and scoring.
Clutch Materials
1. Cotton and asbestos fiber-woven or molded together and impregnated with resins or other
binding agents.
2. Copper wires are woven or pressed into the facing to give added strength.
3. Ceramic or metallic facings.
Considerations in Designing a Friction Clutch
The following considerations must be kept in mind while designing a friction clutch.
1. The suitable material forming the contact surfaces should be selected.
2. The moving parts of the clutch should have low weight in order to minimize the inertia
load, especially in high speed service.
3. The clutch should not require any external force to maintain contact of the friction
surfaces.
4. The provision for taking up wear of the contact surfaces must be provided.
5. The clutch should have provision for facilitating repairs.
6. The clutch should have provision for carrying away the heat generated at the contact
surfaces.
7. The projecting parts of the clutch should be covered by guard.
Clutch Design
Major Design steps:
1. Assuming power transmitted, speed, and space constraints are known.
2. Select suitable clutch liner and fix its friction factor (previous table).
3. Fix the allowable normal pressure between the friction surface (previous table)
4. Assume suitable d/D ratio, if not given select it as 0.577 (for maximum power transmission.)
5. If not specified assume uniform wear condition.
Summary
Summary
Spring Design
Spring Design
• Total stiffness of the springs, s
• s = Stiffness per spring × No. of springs
• Initial compression in the springs = W / s
• D = Mean diameter of the spring, and
• d = Diameter of the spring wire
• In order to allow for adjustment and for maximum engine torque, the spring is designed for an overload of
25%.
• Total load on the springs = 1.25 W
• maximum load on each spring, WS = Total load on the springs/ number of the springs

• Wahl's stress factor =

• Where C is spring index = D/d

• maximum shear stress induced in the wire (τ) =

• Note We shall take a standard wire of size SWG 8 having diameter

Spring Design
δ = Deflection of the spring, as a result of an axial load W.

• n = Number of active coils

• G = Modulus of rigidity for the spring material
It maybe noted that part of the coil which is in contact with the seat does not
contribute to spring action and hence are termed as inactive coils. The turns which
impart spring action are known as active turns.
Spring Design
The end connections for compression helical springs are suitably formed in order to apply the
load. Various forms of end connections
Spring Design
Total number of turns

Free length. The free length of a compression spring, is the length of the spring in the free or unloaded
condition = LF = Solid length + Maximum compression + *Clearance between adjacent coils (or clash

allowance) = pitch of the coils =

Shaft Design
• The torque transmitted (T) =
• ds = Diameter of the shaft
• τ1 = Shear stress for the shaft material