CDTC REVIEW CENTER

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DISC ( Friction ) CLUTCH

A clutch refers to a mechanical device operated by the clutch pedal designed to engage and disengage the engine.

Disc clutch is a rounded plate used to connect the engine of a vehicle to the transmissions input shaft allowing the
temporary separation needed to shift gears. It is a steel plate situated between the pressure plate and flywheel. A hub
in the disc's center fastens over the transmission input shaft's spine. Activating the clutch results in pressure applied
to the disc from the pressure plate and flywheel. This pressure causes engine power to be sent from the disc's hub to
the transmission's input shaft.

Disc clutch facings are covered with a friction material, which typically consists of a compound organic resin with
ceramic material or copper wire facing. A standard coefficient of friction used on clutch disc surfaces is 0.25
micrometers for ceramic and 0.35 micrometers for organic compounds.

Disc clutches are classified as pull type or push type. In push-type disc clutches, pressing the clutch pedal pushes a
release bearing into the clutch, which disengages the vehicle drive. Pressing the clutch pedal in a pull-type disc clutch
pulls the release bearing, which in turn pulls the spring in the diaphragm and disengages the drive.

For New DISC CLUTCH ( to be designed )

1. Uniformly distributed pressure theory

Illustration:

Single plate ( or disc ) clutch

Fa
P=
A

where:
Fa = axial force
Fs = spring force
Fn = normal force
and,
Fa = Fs = Fn
[1]
Fa = P ( A )

Fa = P ( dA )

where:
A – area under pressure
dA = 2 p r dr
D = outside ( larger ) diameter
d = inside ( smaller ) diameter
Dm = mean diameter

Fa = P ( 2 p r dr ) [1]

D/2
Fa = 2 p P ò r dr
d/2

r2 D/2

Fa = 2 p P
2 d/2

( D/2 )2 – ( d/2 )2
Fa = 2 p P
2

D2 – d2 D2 – d2
Fa = 2 p P =pP [2]
8 4

the pressure produced by the mating surfaces because of axial load Fa:

Fa Fa
P= = [3]
D2 – d2 D2 – d2
2p p
8 4

Torque transmitted ( or rating )

T = Ff x rf

where:
Ff = f ( Fn )
but:
Fn = Fa

T = f ( Fn ) r = f ( Fa ) r [4]

substituting eqn. [1] to [4]:

T=f(P)(2prdr) r

T = f ( P ) ( 2 p r2 dr )

[2]
 D/2
T=f(2p)(P)ò r2 dr
d/2

D/2
r3
T=f(2p)(P)
3 d/2

( D/2)3 – ( d/2 )3
T=f(2p)(P)
3

D3 – d3
T=f(2p)(P) [5]
24

substituting eqn. [3] to [5]:

Fa D3 – d3
T=f(2p)
D2 – d2 24
2p
8

D3 – d3

24
T = f ( Fa )
D2 – d2

8 D3 – d3
T = f ( Fa )
24 D2 – d2

hence:

D3 – d3
T = f ( Fa ) [6]
3 ( D2 – d2 )

therefore: the torque transmitted ( or rating ) for multiple disc clutch

substituting eqn. [2] to [6]:

D2 – d2 D3 – d3
T=f p P x NC = f ( Fn ) rf x NC
4 3 ( D2 – d2 )

where:
NC – number of pairs of friction ( or contact ) surfaces
NC = ( number of disc in the driver + number of disc in the Driven ) – 1
NC = total number of discs – 1

[3]
 as previously derived,

D2 – d2
Fn = Fa = p P
4

and, the frictional radius

D3 – d3
rf =
3 ( D2 – d2 )

Note:
For a single plate ( or disc ) clutch, normally both sides of the disc are effective. Therefore a
single plate clutch has two pairs of surfaces in contact ( i.e. NC = 2 ).

[4]
 FOR OLD DISC CLUTCH ( already installed )

2. Uniform wear theory

Illustration:

Fa
P=
A

Fa = P ( A )

Fa = P ( dA )

where:
A – area under pressure
dA = 2 p r dr
D = outside ( larger ) diameter
d = inside ( smaller ) diameter
Dm = mean diameter

Fa = P ( 2 p r dr ) = 2 p P r dr [1]

where:
Wear constant, W = P r = Pmax ( d/2 ) = Pave ( Dm/2 ) = Pmin ( D/2 )
D/2
Fa = 2 p ( P r ) ò dr
d/2

D/2
Fa = 2 p ( P r ) r
d/2

Fa = 2 p ( P r ) ( D/2 – d/2 )

D–d
Fa = 2 p ( P r )
2

Fa = p ( P r ) ( D – d ) [2]

Fa = p Pmax ( d/2 ) ( D – d ) = p Pave ( Dm/2 ) ( D – d ) = p Pmin ( D/2 ) ( D – d )

[5]
the pressure produced by the mating surfaces because of the load Fa:

Fa Fa
P= = [3]
D–d πr(D–d)
2πr
2

Fa Fa Fa
Pmax = ; Pave = ; Pmin = [3']
π ( d/2 ) ( D – d ) π ( Dm/2 ) ( D – d ) π ( D/2 ) ( D – d )

Torque transmitted ( or rating )

T = Ff x rf

where:
Ff = f ( Fn )
but:
Fn = Fa

T = f ( Fn ) r = f ( Fa ) r [4]

substituting eqn. [1] to [4]:

T = f P ( 2 p r dr )
D/2
T=f(2p)(Pr)ò r dr
d/2

r2 D/2
T=f(2p)(Pr)
2 d/2

( D/2 )2 – ( d/2 )2
T=f(2p)(Pr)
2

( D2 – d2 )
T=f(2p)(Pr) [5]
8

substituting eqn. [3] to [5]:

Fa D2 – d2
T = f( 2 p ) (r)
D–d 8
2p(r)
2

D2 – d2

8 2 ( D2 – d2 ) (D+d)(D–d)
T = f ( Fa ) = f ( Fa ) = f ( Fa )
D–d 8 D–d 4(D–d)

2
[6]
therefore: the torque transmitted ( or rating ) for a multiple disc clutch

D+d
T = f ( Fa ) x NC [6]
4

D+d
T=fp(Pr)(D–d) x NC
4

where:
Wear constant, W = P r = Pmax ( d/2 ) = Pave ( Dm/2 ) = Pmin ( D/2 )

D+d
T = f p Pmax ( d/2 ) ( D – d ) x NC
4
or,
D+d
T = f p Pave ( Dm/2 ) ( D – d ) x NC
4
or,
D+d
T = f p Pmin ( D/2 ) ( D – d ) x NC
4

where:
NC – number of pairs of friction ( or contact ) surfaces
NC = ( number of disc in the driver + number of disc in the Driven ) – 1
NC = total number of discs – 1

as previously derived,

Fa = Fn = p Pmax ( d/2 ) ( D – d ) = p Pave ( Dm/2 ) ( D – d ) = p Pmin ( D/2 ) ( D – d )

and, the frictional radius

D+d
rf = = mean radius, rm = ( Dm/2 )
4

Note:
1. For a single plate ( or disc ) clutch, normally both sides of the disc are effective. Therefore a single
plate clutch has two pairs of surfaces in contact ( i.e. NC = 2 ).

2. The uniform pressure theory gives a higher friction torque than the uniform wear theory. Therefore
in case of friction clutches, uniform wear should be considered, unless otherwise stated.

[7]
 CDTC REVIEW CENTER
"Excellence Through Quality Review"

CONE ( Friction ) CLUTCH

Cone clutch serves the same purpose as a disk or plate clutch. However, instead of mating two spinning disks, the cone
clutch uses two conical surfaces to transmit torque by friction.

Cone clutch is a clutch which uses the wedging action of mating conical surfaces to transmit friction torque.

Cone clutch is a friction clutch consisting of a cone that fits inside a cup when engaged. Cone clutches are less
expensive than disk styles but can be difficult to disengage.

The cone clutch transfers a higher torque than plate or disk clutches of the same size due to the wedging action and
increased surface area. Cone clutches are generally now only used in low peripheral speed applications although they
were once common in automobiles and other combustion engine transmissions.

They are usually now confined to very specialist transmissions in racing, rallying, or in extreme off-road vehicles,
although they are common in power boats. This is because the clutch does not have to be pushed in all the way and the
gears will be changed quicker. Small cone clutches are used in synchronizer mechanisms in manual transmissions.

Schematic drawing of a cone clutch

1. Cones: female cone ( green ), male cone ( blue )

2. Shaft: male cone is sliding on splines

3. Friction material: usually on female cone, here on male cone

4. Spring: brings the male cone back after using the clutch control

5. Clutch control: separating both cones by pressing

6. Rotating direction: both direction of the axis are possible

[8]
 FOR NEW CONE CLUTCH ( to be designed )

1. Uniformly distributed pressure theory

Illustration:

Fa
P=
A

Fa = P ( A )

Fa = P ( dA )

where:
A – area under pressure
dA = 2 p r dr
D = outside ( larger ) diameter
d = inside ( smaller ) diameter

Fa = P ( 2 p r dr ) [1]

D/2
Fa = 2 p P ò r dr
d/2

r2 D/2

Fa = 2 p P
2 d/2

(D/2)2 – (d/2)2
Fa = 2 p P
2

D2 – d2
Fa = 2 p P
8

D2 – d2
Fa = p P [2]
4

[9]
the pressure produced by the mating surfaces because of axial force ( load ) Fa:

Fa Fa
P= = [3]
D2 – d2 D2 – d2
2p p
8 4

Torque transmitted ( or rating )

T = Ff x rf

where:
Ff = Frictional force = f ( Fn )
f = coefficient of friction
Fn = normal force ( load )
a = cone angle

but:
Fa
sin a =
Fn

Fa
Fn =
sin a
Fa
T = f ( Fn ) r = f r [4]
sin a

substituting eqn. [1] to [4]:

(P)(2prdr)
T=f r
sin a

( P ) ( 2 p r2 dr )
T=f
sin a

(2p)(P) D/2
T=f ò r2 dr
d/2
sin a
D/2
(2p)(P) r3
T=f
sin a 3 d/2

(2p)(P) ( D/2)3 – ( d/2 )3

T=f
sin a 3

(2p)(P) D3 – d3
T=f [5]
sin a 24

[10]
substituting eqn. [3] to [5]:

Fa
2p
D2 – d2
2p
8 D3 – d3
T=f
sin a 24

D3 – d3

( Fa ) 24
T=f
sin a D2 – d2

( Fa ) 8 D3 – d3
T=f
sina 24 D2 – d2

hence:

( Fa ) D3 – d3
T=f [6]
sin a 3 ( D2 – d2 )

therefore: the torque transmitted ( or rating ) for one pair of contact surfaces

substituting eqn. [2] to [6]:

D2 – d2
pP
4 D3 – d3
T=f = f ( Fn ) rf
sin a 3 ( D2 – d2 )

where:

D2 – d2
pP
4
Fn =
sin a

and, the frictional radius

D3 – d3
rf =
3 ( D2 – d2 )

[11]
 FOR OLD CONE CLUTCH ( already installed )
2. Uniform wear theory
Illustration:

Fa
P=
A

Fa = P ( A )

Fa = P ( dA )

where:
A – area under pressure
dA = 2 p r dr
D = outside ( larger ) diameter
d = inside ( smaller ) diameter

Fa = P ( 2 p r dr ) = 2 p P r dr [1]

where:
Wear constant, W = P r = Pmax ( d/2 ) = Pave ( Dm/2 ) = Pmin ( D/2 )
D/2
Fa = 2 p ( P r ) ò dr
d/2

D/2
Fa = 2 p ( P r ) r
d/2

Fa = 2 p ( P r ) ( D/2 – d/2 )

D–d
Fa = 2 p ( P r )
2

Fa = p ( P r ) ( D – d ) [2]

Fa = p Pmax ( d/2 ) ( D – d ) = p Pave ( Dm/2 ) ( D – d ) = p Pmin ( D/2 ) ( D – d )

[12]
the pressure produced by the mating surfaces because of the force ( load ) Fa:

Fa
P=
πr(D–d)

Fa Fa Fa
Pmax = ; Pave = ; Pmin = [3]
π ( d/2 ) ( D – d ) π ( Dm/2 ) ( D – d ) π ( D/2 ) ( D – d )

Torque transmitted ( or rating )

T = Ff x rf

where:
Ff = Frictional force = f ( Fn )
f = coefficient of friction
Fn = normal force ( load )
a = cone angle

but:
Fa
sin a =
Fn

Fa
Fn =
sin a

Fa
T = f ( Fn ) r = f r [4]
sin a

substituting eqn. [1] to [4]:

P ( 2 p r dr )
T=f r
sin a

(2p)(Pr) D/2
T=f ò r dr
d/2
sin a

( 2 p ) ( P r ) r2 D/2

T=f
sin a 2 d/2

(2p)(Pr) ( D/2 )2 – ( d/2 )2

T=f
sin a 2

(2p)(Pr) ( D2 – d2 )
T=f [5]
sin a 8

[13]
 substituting eqn. [3] to [5]:

Fa
(2p) (r)
D–d
2p(r)
2 D2 – d2
T=f
sin a 8

D2 – d2

( Fa ) 8 ( Fa ) 2 ( D2 – d2 ) ( Fa ) (D+d)(D–d)
T=f =f =f
sin a D–d sin a 8 D–d sin a 4(D–d)

therefore: the torque transmitted ( or rating ) for one pair of contact surfaces

( Fa ) (D+d)
T=f [6]
sin a 4

substituting eqn. [2] to [6] :

p (Pr) (D–d) D+d

T=f
sin a 4

where:
Wear constant, W = P r = Pmax ( d/2 ) = Pave ( Dm/2 )= Pmin ( D/2 )

p Pmax ( d/2 ) ( D – d ) D+d

T=f
sin a 4
or,
p Pave ( Dm/2 ) ( D – d ) D+d
T=f
sin a 4
or,
p Pmin ( D/2 ) ( D – d ) D+d
T=f
sin a 4

where:

p Pmax ( d/2 ) ( D – d ) p Pave ( Dm/2 ) ( D – d ) p Pmin ( D/2 ) ( D – d )

Fn = = =
sin a sin a sin a

and, the frictional radius

D+d
rf = = mean radius, rm = ( Dm/2 )
4

[14]
Force to engage the clutch

Illustration:

Fe = Fa + Ff h

Fe = Fn sin a + Ff cos a

Fe = Fn sin a + f ( Fn ) cos a

Fe = Fn sin a + f cos a

Note:
Actual experiment shows the f cos a is only 25% effective.

therefore:

Fe = Fn sin a + 0.25 f cos a

Note:

1. The uniform pressure theory gives a higher friction torque than the uniform wear theory. Therefore
in case of friction clutches, uniform wear should be considered, unless otherwise stated.

2. Cone angle usual range: 7 1/20 – 12 1/20 ( SAE recommends 12 1/20 )

[15]