GANDHINAGAR INSTITUTE OF

TECHNOLOGY

MECHANICAL DEPARTMENT

THEORY OF MACHINES (2151902)

Active Learning Assignment
On
CLUTCHES
PREPAIRED BY: GUIDED BY:

KAUSHAL KAKADIYA (130120119079) PROF. AMIT PATEL

HARSHIL KACHHA (13012019075)

DEWAL JOSHI (130120119074)

 CLUTCHES
PREPAIRED BY:

KAUSHAL KAKADIYA (130120119079)

HARSHIL KACHHA (13012019075)

DEWAL JOSHI (130120119074)

 BASIC DIFFERENCE BETWEEN
COUPLING,CLUTCHES, BRAKES
A coupling such as a flange coupling, is a permanent connection. the driving and driven
shafts are permanently attached by means of coupling and it is not possible to disconnect the
shafts , unless the coupling dismantled.
On the other hand , the clutch can connect or disconnect the driving and driven shafts , as
and when required by the operator.

In the operation of clutch ,the condition are follows:

Initial condition: the driving member is rotating and the driven member is at rest.
Final condition : both members rotate at the same speed and no relative motion.
In the operation of brake ,the condition are follows:
Initial condition : one member such as the brake drum is rotating and the braking member
such as the brake shoe is at rest.
Final condition : both members are at rest and have no relative motion.
 WHAT IS CLUTCHES ?
A clutch is a mechanical device that engages and disengages the power transmission ,
especially from driving shaft to driven shaft.

In the simplest application, clutches connect and disconnect two rotating shafts (drive
shafts or line shafts). In these devices, one shaft is typically attached to an engine or other
power unit (the driving member) while the other shaft (the driven member) provides
output power for work.
 PRINCIPLE OF CLUTCH
It operates on the principle of friction. When two surfaces are brought in
contact and are held against each other due to friction between them, they can
be used to transmit power. If one is rotated, then other also rotates. One
surface is connected to engine and other to the transmission system of
automobile. Thus, clutch is nothing but a combination of two friction surfaces .
 MAIN PARTS OF A CLUTCH
It consists of
(a) a driving member,
(b) a driven member, and
(c) an operating member.

Driving member has a flywheel which is mounted on the engine crankshaft. A

disc is bolted to flywheel which is known as pressure plate or driving disc.

The driven member is a disc called clutch plate. This plate can slide freely to
and fro on the clutch shaft.

The operating member consists of a pedal or lever which can be pressed to

disengaged the driving and driven plate.
 TYPES OF CLUTCHES
1)Mechanical clutches
2)Pneumatic clutches
3)Hydraulic clutches
4)Electromagnetic clutches

Mechanical clutches
1)Positive contact clutches
i. jaw clutches
ii.toothed clutches
2)Friction clutches
i.Disc clutches
ii.Cone clutches
iii.centrifugal clutches
 System Components
Flywheel: Transfers engine power to the clutch

Input shaft: Transfers power from clutch to the transmission

Clutch Disk (clutch): Splined to input shaft; transfers power from

engine to the input shaft

Pressure Plate Assembly: Spring pressure tightly holds the clutch to

the flywheel
 Components cont:
Release Bearing (throw-out bearing): Connected through linkage
or hydraulics to the clutch pedal; Provides a way for the pressure
plate to release pressure on the clutch

Pilot Bearing (bushing) : Mounted in the tail of the crankshaft.

Stabilizes the input shaft. Not always used for FWD.

Clutch Fork (if applicable): Slides the release bearing into and
away from the pressure plate assembly
 Components cont:
Clutch Linkage (or hydraulic plumbing): Allows the driver to
operate the clutch fork

Clutch (bell-housing) Housing: Encloses the clutch assembly

May be integral with the transmission or removable
Clutch Components - Flywheel
Mounted on the rear of the
crankshaft
Acts as balancer for engine
Adds inertia to the rotating
crankshaft
Provides a surface for the
clutch to contact
Usually surrounded by a ring
gear for electric starter
operation
 Flywheel Construction
Usually constructed of
nodular cast iron which
has a high graphite content
The graphite helps
lubricate engagement of
the clutch
May also be constructed
from cold rolled steel
 Clutch Disc Types
Rigid - used primarily
for industrial/racing
applications.
Flexible - most common,
everything from
grandmas cruiser to
street/strip racing.
 Flexible Clutch Disc

Hub flange - in direct contact with the input shaft

Friction ring - in direct contact with the flywheel/pressure plate.
 Flexible Clutch Disc
Clutch facing - friction material
marcel springs - facing dampener

Torsional springs - further dampening for clutch application

Stop pins - limits the torsional springs travel
Rivets -fastens the facing material to marcel (springs)
Belleville/diaphragm Spring:
Spring-type Pressure Plate
 Benefits and Disadvantages:

Belleville/diaphragm type:
cost effective
uniform engagement
limited spring pressure
Spring:
unlimited pressure capabilities
as springs wear, pressure may become
inconsistent
Clutch Components
Release (throw-out) bearing

Operated by the clutch linkage

Presses against the pressure plate to release
the clutch
 Clutch Components
Pilot Bearing (bushing)

Installed (pressed) into a machined bore in the

end of the crankshaft or flywheel
May be a bushing, ball-bearing or roller-bearing
Clutch linkage Mechanical
Linkage-type
Clutch linkage Mechanical
Cable-type
 SINGLE PLATE CLUTCH
A single plate is commonly used in cars and light vehicles. It has only one clutch plate
which is mounted on the splines of the clutch shaft.
A flywheel is mounted on the crankshaft of the engine. A pressure plate is connected
to the flywheel through the bolts and clutch springs. It is free to slide on the clutch shaft
with the movement of clutch pedal.
When clutch is in engaged position, the clutch plate remains gripped between
flywheel and pressure plate. Friction linings are provided on both the sides of clutch
plate.
On one side clutch plate is in touch with flywheel and on other side with pressure plate.
Due to friction on both sides, the clutch plate revolves with engine flywheel.
Transmission Therefore, clutch transmits engine power to clutch shaft. Clutch shaft is
connected to transmission (or gear box) of automobile. Thus, clutch transmits power from
engine to transmission system which inturn rotates wheels of engine.

When the clutch plate is to be disengaged, the clutch pedal is pressed. Because of this
pressure plate moves back and clutch plate is disengaged from flywheel. Thus, clutch
shaft stops rotating even if engine flywheel is rotating. In this position, power does not
reach the wheels and vehicle also stops running. Single plate clutch is show n fig.
Design of clutch plate

r
R1
R2
R2

R1
 Single Plate Clutch
W=total axial load
R1=External radius of clutch plate
R2=internal radius of the clutch plate
R1
R1
P=intensity of pressure between contacting
surfaces.
=coefficient of friction between contacting
surfaces
Single Plate Clutch
Consider a elemental ring of radius r and
thickness r on the contacting surface.
therefore,
Area of the ring on contacting surface is,
Axial load on the ring is,
W=pressureArea of the ring

W p 2 r r
Single Plate Clutch
Frictional resistance offered by ring is,
Fr W
F (p
Frictional
r
torque r r) on2the ring
2 acting is,
p r r

T r Fr r
Tr 2 p r r.r 2 p r 2 r
Single Plate Clutch
Torque transmitted by single plate clutch is
obtained by considering following two
assumptions
(a)uniform pressure theory
(b)uniform wear theory
Single Plate Clutch
(a)uniform pressure theory:
Assuming that the intensity of pressure over the
entire contacting surface area is constant,
Then,
p=constant
load W
Total
p torque transmitted by single 2 plate clutch

contacting surface area R 1 R 2
can be obtain by integrating Equation
2
Single Plate Clutch
(1)within limit R2 to R1 we
T R1

r
2
2 p r r
0 R2

T R1

r 2 p r
2
r
0 R2
R2
r

3
2
2 p 3 3
p R1 R 2
3 R1
3
[p=Consta
nt]
 2

3
W
2

R1 R 2
2
R 1
3
R 2
3

W
p

2
R1 R 2
2

2
W

R 13 R 2 3
3
2
R1 R 2
2
.(A)

Equation (A) gives the torque transmitted by single plate

clutch due to friction considering uniform pressure theory.
Single Plate Clutch
(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
...(3)
Single Plate Clutch
Axial load acting on the ring is
W=p 2 r r
C
W 2 C r
r
W=2 C (4)
r
Integrating above Equation(4) within limit we get,
w R1

W 2
0 R2
C r
Single Plate Clutch
W 2 C r 2 C R 1 R 2
R1
R2

W
C
We know2 Rfrictional
that 1 R 2 torque acting on ring is,
.(5)

r 2 p r r
2
.(6)
C 2
r 2 r r r 2 C r r
r
Single Plate Clutch
Torque transmitted by single plate clutch can be
obtain by integrating the Equation (4 ) within the
limit R2 to R1 we get,
T R2

0
r 2
R2
C r r

T R2

0
r 2 C r r
R2

2 C
r

2 R1

2 C
R 1
2
R2
2

2 R2
2
Single Plate Clutch

W
2 R 1 R 2
2
R1 R 2
2

1
W
2
R1 R 2
2

2 torque Rtransmitted
This is the 1 R2 by single plate
due 1
tofriction considering uniform wear theory.
W
2
Single Plate Clutch
Power transmitted by single plate clutch is
given by,
P
2 N
P Watt
60
where, N Speed of shaft in rpm
 MULTIPLATE CLUTCH
Multi-plate clutch consists of more than one clutch plates contrary to single plate
clutch which consists of only one plate. Friction surfaces are made in case of multi-
plate clutch. Due to increased number of friction surfaces, a multi-plate clutch can
transmit large torque.

Therefore, it is used in racing cars and heavy motor vehicles witch have high engine
power. The clutch plates are alternatively fitted with engine shaft and the shaft of gear
box. He plates are firmly held by the force of coil springs and they assembled in a
drum.
One plate slides in the grooves on the flywheel and the next plate slides on spines
provided on pressure plate. Thus, each alternate plate slides in grooves on the flywheel
and the other on splines of pressure plate. If we take two consecutive plates, then one has
inner and other has outer splines.
When the clutch pedal is pressed, the pressure plate moves back against the force of
coil spring, hence the clutch plates are disengaged and engine flywheel and gear box are
decoupled. However, when clutch pedal is not pressed the clutch remain in engaged
position and the power can be transmitted from engine flywheel to the gear box. This type
of clutch has been shown in Figure.
 For multiplate clutch
For uniform pressure theory,
2
n W

R 13 R 2 3
For uniform wear theory,
3 R 12
R 2
2

1
n W R 1 R 2
2
 Multiplate Clutch
Notes:
In case of new clutch ,the intensity of pressure is uniform
along the surface of clutch but in case of old clutch
uniform theory is more correct.
For single plate clutch normally both sides of the plate
are effective .there for single plate clutch has two pairs of
contacting surface i.e. n=2.
In actual practice, usually the theory of uniform wear is
used in analysis of clutch.
Intensity of pressure is maximum at the inner radius R2 of the
friction or contact surface,

C
Pmax R 2 C OR Pmax
R2
Intensity of pressure is minimum at the inner radius R1 of the
friction or contact surface,

C
Pmax R 1 C OR Pmax
R1
In mutilate disc clutch
n1 no of disc on driving shaft
n no of disc on driven shaft
2
So no. of pairs in contact,

n n1 n 2 1
Clutch plate
 DIFFERENCE BETWEEN SINGLE
AND MULTI-PLATE CLUTCHES :-
The number of pairs of contacting surfaces in the single plate
clutch is one or at the most, two. These are more number of
contacting surfaces in the multi-disk clutch.
As the number of contacting surfaces is increased, the
torque transmitting capacity is also increased, other conditions
being equal. In other words, for a given torque capacity, the
size of the multi-plate clutch is smaller than that of the single
plate clutch, resulting in compact construction.
 The work done by friction force during engagement is converted
into heat. More heat is generated in the multi-plate clutch due to
increased number of contacting surface. Heat dissipation is a serious
problem in the multi-plate clutch. Therefore, multi-plate clutches are
wet clutches, while single plate clutches are dry.
The coefficient of friction decreases due to cooling oil, thereby
reducing the torque transmitting capacity of the multi-plate clutch.
The coefficient of friction is high in dry single plate clutches.
Single plate clutches are used in applications where large radial
space is a available, such as trucks and cars. Multi-disk clutches are
used in applications where compact construction is desirable, e.g.,
scooter and motorcycle.
 Cone clutch

= semi-apex angle of the

cone
Only one pair of driving
surfaces is possible, n =1

The maximum torque transmitted = T = Wrm cosec

 Centrifugal clutch
Centrifugal clutch F=mr2

Driven
shaft

Driving
shaft
Friction lining

Total friction torque , T = nR(F-P)

Objectives
Diagnose clutch problems before disassembly
Adjust a clutch
Install a replacement clutch
Inspect worn or damaged clutch parts and
determine the cause of the problem
Introduction
Early automobiles
Produced with manual shift transmissions
Required clutch
Some new model cars and light trucks have
manual transmissions
Utilize a clutch as well
Common to have at least one new clutch installed
Clutch work is not difficult to learn
Diagnose problems before and after disassembly
Transmission Noise
Sometimes noise occurs only when engine is
idling in neutral with clutch engaged
Front transmission bearing on input shaft and
mainshaft pilot are only bearings rotating
One of these bearings is probably the noise source
Pedal Problems and Slipping
Clutch
Diagnosis on basis of pedal feel
Pulsating pedal: something internal in clutch
Pedal is hard to depress: binding linkage or cable
Slipping clutch
Tested by putting it in the highest gear range
Several possible reasons clutch slip
Partial engagement
Partial disengagement
Dragging Clutch
Clutch drags: does not release properly
Disc stays attached to the flywheel
Test for a dragging clutch
Start engine and run it to normal operating
temperature
Engine at idle and transmission in neutral: depress
clutch to floor
Wait ten seconds
Shift transmission into reverse
Oily Clutch Facings
Oil leaking onto clutch disc:
Causes clutch slipping
Disc may overheat and burn its friction surface
During repair:
Disc and pressure plate are replaced
Rest of the parts are thoroughly cleaned
Determine and repair oil leak source
Oil on front side of flywheel: crankshaft rear seal or
external engine leak
Oil on rear side of flywheel: bad front transmission seal
or overfilled transmission
Damaged Friction Surfaces
Damage to friction surfaces of clutch cover or
flywheel can cause clutch to slip
Clutch slips: heat is generated
Flywheel or pressure plate can be warped
Flywheel, pressure plate, or disc can all become glazed
Flywheel is commonly resurfaced
Chattering or Grabbing
Clutch
Chattering clutch
Occurs when pedal shakes as clutch is engaged
Grabbing clutch
Occurs when friction disc does not slip normally
but grabs all at once
Causes of clutch chatter or grabbing
Oil on friction lining
Worn or broken motor mounts
Worn or bent clutch fork
Clutch Service
Includes:
Checking and adjusting free play and travel
Hydraulic component service
Clutch replacement
Some clutches require adjustment
As the disc wears, it becomes thinner
Results in release levers moving closer to the release
bearing which means less clearance
Servicing Hydraulic
Components
Internal hydraulic system problems
Usually the result of dirty or aging internal rubber
sealing parts
Master cylinder and slave cylinder
Either can develop leaks
Different methods can be used to bleed air from
a clutch hydraulic system
Gravity bleeding
Clutch Replacement
Includes replacement of several parts
Disc
Release bearing
Clutch cover
Pilot bearing or bushing
Sometimes a flywheel and/or front transmission
seal
Often come in a clutch parts kit
 RESEARCH PAPER

Design and Analysis of Clutch Using Sintered Iron as a Friction Material

 ABSTRACT
Clutch system is among the main systems inside
a vehicle. Clutch is a mechanical device located
between a vehicle engine and its transmission
and provides mechanical coupling between the
engine and transmission input shaft. Clutch
system comprise of flywheel, clutch disc plate
and friction material, pressure plate, clutch
cover, diaphragm spring and the linkage
necessary to operate the clutch. The clutch
engages the transmission gradually by allowing a
 AUTOMOTIVE CLUTCH
SYSTEM
Automotive clutches are located between the
engine and the transmission. It provides
mechanical coupling between the engine and
transmission input shaft. Manual transmission
cars need a clutch to enable engaging and
disengaging the transmission. The clutch
engages the transmission gradually by allowing a
certain amount of slippage between the flywheel
and the transmission input shaft (Erjavec
2005).Clutch basically consists of six major
 CLUTCH MATERIALS
The clutch disc is generally made from grey
cast iron (Afferante et al. 2003; Poser et al.
2005). This is because grey cast iron has a good
wear resistance with high thermal conductivity
and the production cost is low compare to other
clutch disc materials such as A1-MMC
(aluminum-metal matrix composite), carbon
composites and ceramic based composites
(Terhech et al. 1995; Jang et al. 2003). High
thermal conductivity of diffusivity of the
 SINTERED FRICITON
MATERIL
Friction pads are manufactured by sintering
blend of powders consisting of heat absorption
material along with friction generating &
lubricating materials. The powders are blended
in optimized proportions & compacted to form a
solid flat button of predetermined shape. They
are highly durable with harsher engagement
characteristics compared to organic linings. The
quality of materials used along with the sintering
parameter play an important role in providing the
 Method Of Analysis
The torque that can be transmitted by a clutch is
a function of its geometry & the magnitude of
the actuating force applied as well the condition
of contact prevailing between the members. The
applied force can keep the members together
with a uniform pressure all over its contact area
& the consequent analysis is based on uniform
pressure condition. However as the time
progresses some wear takes place between the
contacting members & this may alter or vary the
Single plate
clutch
CONCLUSION
CONCLUSION CONT..
 REFERENCES

[1] Machine Design II, by Prof. K.Gopinath &

Prof. M. M. Mayuram
[2] K Tripathi, Design Optimization of Friction
Clutch
[3] United States Patent Office On - Auxiliary
drive clutch mechanism
[4] Arvind vadiraj Engagement characteristic
of friction pad for the commercial vehicle clutch
 Any
quetion