MV 6141

VEHICLE SYSTEMS

CHAPTER-8
THEORY AND DESIGN OF CLUTCH

Taught by LTC Dr. Menelik Walle

Dept. of Motor Vehicle Engineering
Defence University, College of Engineering
Email: [email protected]
Mobile: +251991069839
All Rights Reserved
 INTRODUCTION TO CHLUTCH

A clutch is a mechanical device that engages and disengages the power transmission, especially from driving shaft to driven
shaft. Or, A clutch is a mechanism which enables the rotary motion of one shaft to be transmitted to second shaft, whose axis
is coincident with that of first.
The clutch is located b/w the engine and gear box.
oWhen the clutch is engaged, the power flows from the engine to the rear wheels through the transmission system and the
vehicle moves. The clutch is engaged only when the vehicle is to move and is kept engaged when the vehicle is moving.
oWhen the clutch is disengaged, the power is not transmitted to the rear wheels and the vehicle stops while the engine is still
running. The clutch is disengaged :-
i. When starting the engine.
ii. When shifting the gears.
iii. When stopping the vehicle.
iv. When idling the engine.
 The clutch also permits the gradual taking up of the load. When properly operated, it prevents jerky motion of the
vehicle.
INTRODUCTION TO CHLUTCH
WORKING PRINCIPLE OF CHLUTCH

The clutch disengages and engages the engine to the transmission

 CLUTCH
Function of Clutch

Clutch used
To permit engagement or disengagement of a gear when the vehicle is stationary and the
engine is running. Or
To transmit the engine power to the road wheels smoothly without shock to the transmission
system while setting the wheel in motion.
To permit the engaging of gears when the vehicle is in motion without damaging the gear
wheels.
In short,
 To transmit engine drive to gearbox.
To disengage engine drive for change of gears, and reduction of speed.
 CLUTCH
Requirements of a Clutch
oMaximum torque: Transmit maximum torque of the engine.
oGradual engagement: It should be engage gradually to avoid sudden jerks.
oLow clutch pedal pressure: It should be easily operated (i.e. it should consume minimum physical effort at the
time of engagement and disengagement)
oHeat dissipation: It should be able to dissipate large/ maximum amount of heat which is generated during the
clutch operation due to friction.
oTorsional Damping: It should be suitable mechanism to damp vibrations and to eliminated noise produced
during the power transmission.
oDynamic balancing: It should be dynamically balanced (particularly required in case of high speed engine
clutches)
oCentrifugal Force:it should be free from slip when engaged.
oCompact size.: It should be small as possible so that it will occupy minimum space.
oEase of operation: It should be easily accessible and have simple means of adjustment (Easy to operate).
oLong life.: The wearing surfaces should have long life.
 CLUTCH
Types of Clutch
 CLUTCH
Types of Clutches
Types based on engagement:- (a) Mechanical friction clutch. e.g.
(1) Positive Clutch
 dry/wet,
 Jaw/ claw clutch
 single/multi plate
(2) Progressive Type Clutch
 Between Engine and Gear Box
 Centrifugal Clutch
a) Fluid coupling  Cone clutch
b) Friction clutch : (b) Hydraulic clutch
 Disc / plate clutch (c) Electrical/Magnetic clutch.
 Cone clutch (d) Vacuum clutch
 Centrifugal clutch
 CLUTCH
Types of Clutches
Positive contact / engagement/ Clutches:
oThe positive clutches are used when a positive drive is
required.
oThe simplest type of a positive clutch is a jaw or claw
clutch.
oThe jaw clutch permits one shaft to drive another
through a direct contact of interlocking jaws.
oA square jaw type of clutch will transmit power in either
direction of rotation.
oThe spiral jaws may be left-hand or right-hand, because
power transmitted by them in one direction only.
Jaw/claw clutch
 CLUTCH
Types of Clutches
Positive contact / engagement/ Clutches:
oTransmit power from the driving shaft to the driven shaft by means of jaws or teeth
Transmit large torque with no slip
Develop very little heat, because they do not depend upon friction
Generally lighter
Less costly than a friction clutches of similar torque capacity
Can not be engaged at high speeds, max 60 rpm for jaw clutches, and 300 rpm for
toothed clutches
Shock accompanies engagement at any speed
Require some relative motion in order to engage when both driving and driven shafts are at
rest
 CLUTCH
Types of Clutches
Positive contact / engagement/ Clutches:
Although not as widely used as friction clutches, do find important use in such applications as
automotive transmissions, presses, household appliances
A synchromesh clutch in a manual automotive transmission: combined with a friction-type
clutch, which drags the two elements to nearly the same velocity before the jaws or teeth
engages.
Automotive transmission typically use helical gears, for quiet operation.
The helical gears can not be easily shifted in and out of engagement in manual
transmission because of their helix angle.
Each gear has a synchromesh clutch connecting it to its shaft.
 FRICTION CLUTCH
Clutch Arrangement

TXN assembled with engine

 FRICTION CLUTCH
Disc Clutch

Pressure Plate

 Springs help to isolate the txn from

shock of the clutch engaging
 FRICTION CLUTCH
Disc Clutch

 Wire operated clutch  Hydraulic operated clutch

 FRICTION CLUTCH
Single plate or Disc Clutch
 Construction or Line diagram of single plate clutch
 FRICTION CLUTCH
Disc Clutch
The clutch disc is squeezed against the flywheel by Pushing on the pedal moves the pivot lever to pull
spring pressure when the pedal is up the pressure plate away from the disc.
 CLUTCH
Multiplate Clutch
The multi-plate clutch is an extension of single plate It consists of a number of clutch plate, instead of only
one clutch plate as in the case of single clutch plate. The increase in the number of friction surfaces obviously
increase capacity of the clutch to transmit torque, the size remaining fixed.
oThe plates are alternately fitted to the engine shaft and gear box shaft. Each of the alternate plate slides in
grooves on the flywheel and the other slides on splines on the pressure plate.
o Alternatively, the overall diameter of the clutch is reduced for the same torque transmission as a
single plate clutch.
This type of clutch is, used in some heavy transport vehicles, in epicyclic gearboxes and racing cars
where high torque is to be transmitted. Besides, this finds applications in case of scooters and
motorcycles, where space available is limited.
oThe plates of multi-plate clutch were made of steel and phosphor bronze alternately but now are all of
steel or one set may be lined with a friction material.
• With metal to metal contact lubrication is essential. So clutch is made oil-tight and partly filled with oil. The
oil tends to make the Plates drag when clutch is disengaged so a clutch stop (or) brake is fitted to avoid this
drag.
 CLUTCH
Multiplate Clutch
 CLUTCH
Multiplate Clutch
Working of multiplate clutch:
 The drum is supported on a spigot extension of the crankshaft with a bush bearing. Between the web of
inner drum and a sleeve screwed in to the cover plate of the outer drum is a strong coil spring. Thus inner
drum is pressed to left, squeezing both outer and inner plates. Thus driving torque is transmitted due to
friction between the plates.
 The clutch is disengaged by pulling inner drum right against spring force.
oClutch plate engaged with the flywheel and torque is transmitted from the through friction facing to the transmission
input shaft. Hence the wheel of the car also rotates. When the clutch pedal is pressed the release bearing acts on
the pressure plates diaphragms and move the pressure plates away from the flywheel.
This release bearing the clamping force on the facings plate and separator plate and allows flywheel to freely
without turning the clutch shaft. Now the clutch plate disengage with the flywheel, and drive is no longer
transmitted.
When the pedal is released, the spring tension forces the pressure plates, clutch plates and separator plates
against the flywheel, clamping all components together.
 CLUTCH
Clutch Fundamentals
 In a clutch, it has driving and driven member.
Driving Members:
Pressure-plate assembly and the flywheel – bolted together such that the assembly rotates at the
speed of the engine.
The types of pressure plate:
(a) Coil pressure-spring type.
 Consist of a cover, the pressure springs, a pressure plate and release levers.
 All the above parts are assembled inside the cover.
 Requires over 8000 kPa pressure to hold the clutch disc against the flywheel.
(b) Diaphragm-spring type.
 Incorporates a diaphragm spring,
 Works as both pressure springs and release levers.
 CLUTCH
Clutch Fundamentals
Driven Member: consists of a disc or plate assembly and the clutch shaft.
For a disk clutch,
oA driven plate assembly is held between the flywheel and the pressure-plate assembly under the action of pressure
springs.
oThe power picked up by clutch plate is transmitted through steel hub to clutch shaft.
oThe clutch lining materials are mainly asbestos fibres and use reinforcements like brass or copper for longer life.
oThese are attached to the hub, which incorporates a cushioning device and a torsional vibration damping unit.
oThe cushioning permits smooth engagement of the clutch and eliminates clutch chatter.
oThe torsional device absorbs the torsional vibrations of the crankshaft so that they are not transmitted further.
o Clutch linings operating against cast iron have a coefficient of friction.
Operating Member: The operating member consists of release bearing, release lever, foot pedal, linkage and the
spring with adjuster. The clutch pedal is connected through its linkage to release bearing.
 CLUTCH
Centrifugal Clutch
 In this type of clutches the springs are eliminated altogether and
only the centrifugal force is used to apply the required
pressure for keeping the clutch in engagement position.
oThe advantage of the centrifugal clutch is that no separate
clutch pedal is required.
oThe clutch is operated automatically depending upon the
engine speed. This means that car can be stopped in gear without
stalling the engine.
oSimilarly while starting, the driver can first select the gear, put
the car into the gear and simply press the accelerator pedal.
This makes the driving operation very easy.
o Figure left shows a schematic diagram of a centrifugal clutch.
As the speed increases, the weight flying, thereby operating
the bell crank lever that presses the plate.
 CLUTCH
Centrifugal Clutch
oA clutch is a machine member used to connect the driving shaft to a driven shaft, so that the driven shaft
may be started or stopped at will, without stopping the driving shaft.
A clutch provides an interruptible connection between two shafts. The centrifugal clutch is usually used
into motor pulley.
It consists of number of shoe on the inside of a rim of pulley. The outer surface of pulley is covered with
friction material. These shoes which can move radialy in guides are held against the boss on the driving
shaft by means of springs.
oThe spring exert a radialy inward force which assumed to be constant. The weight shoes when revolving
cause it to exert a radialy outward force (centrifugal force).
oThe magnitude of centrifugal force depended on speed at which shoes is revolving. A little consideration
show that when centrifugal force is less than the spring force, the shoes remain same position as when
driving shaft was stationary, but when centrifugal force is equal to spring force, spring is floating.
 CLUTCH
Figure: Centrifugal clutch
Centrifugal Clutch
 It uses centrifugal force produced due to spin of centrifugal
weights to connect / engage the driving and the driven
member.
 Friction elements are thrown radially outward against the
inside of a cylindrical drum to engage the clutch.
 Centrifugal clutches are often used in mopeds, lawnmowers,
chain saw and mini bikes.
 CLUTCH
Fundamental of Centrifugal Clutch
Construction.
a) It consists of a clutch hub mounted on engine crank shaft with 6-8 clutch shoes loosely connected at its
circumference through rivets.
b) The flyweights/clutch shoes are pivoted on the clutch hub and kept in place by garter spring. The
flyweights have friction pads/liners on top (riveted).
c) The flyweights are free to move upwards in the clearance space provided between the friction liner and the
driven drum.
d) A one way clutch is mounted between the flywheel and the driven drum.
Advantage
 Automatic operation.
 Dispense with clutch pedal and clutch disengagement mechanism.
 Simple construction.
Disadvantages
 One way clutch essential for engine braking and tow starting.
 Time gap for clutch disengagement results in difficulty in changing gears.
 CLUTCH
Fundamental of Centrifugal Clutch
Operation.
a) When the engine start rotating, the flyweights on clutch hub start rotating and experience centrifugal
force. These flyweights will start moving outwards when centrifugal force is more than spring force and will
engage with driven drum and transmit power.
b) Thus drive from Engine is transmitted to Gear Box.
c) The power transmission depends upon the Centrifugal force (Engine Speed), Coeff of Friction between
frictional pads and driven drum surface, area of friction.
d) The centrifugal clutch gets engaged and disengaged automatically based on engine speed and there is no
requirement clutch pedal. Hence it is known as automatic clutch.
e) One way clutch slips when engine is driving the Gear Box while it engages otherwise, as there will not be
any centrifugal action unless engine rotates. Used for tow starting and engine braking.
 To ensure that the clutch is engaged at desired speed
 To disengage the clutch when the engine speed falls below a certain speed
 CLUTCH
Cone plate Clutch
 Cone clutches are friction clutches. They are simple in construction and are easy to disengage.
However, the driving and driven shafts must be perfectly coaxial for efficient functioning of the clutch.
This requirement is more critical for cone clutch compared to single plate friction clutch.
 Cone clutch consists of friction surfaces in form of inner and outer cones.
o The engine shaft consists of a female cone (outer cone).
o The male cone (inner cone) is mounted on the splined clutch shaft. It has friction surfaces on the conical
portion. The male cone can slide on the clutch shaft or the inner cone is free to slide axially on the
driven (output--clutch shaft) shaft due to splines.
 When the clutch is engaged the friction surfaces of the male cone are in contact with that of the
female cone due to the force of spring.
 When the clutch pedal is pressed, the male cone slides against the spring force and the clutch is
disengaged.
 CLUTCH
Cone plate Clutch
 CULTCH
Cone plate Clutch
 A 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 friction and torque.
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.
 CULTCH
Working of Cone Plate Clutch

oThe outer cone (female cone) is fastened to the driving shaft and the inner cone (male cone) is free to
slide axially on the driven (output) shaft or clutch shaft due to splines.
oA spring provides the necessary axial force to the inner cone to press against the outer cone, thus
engaging the clutch.
oA contact lever is used to disengage the clutch.
oThe inner cone surface is lined with friction material. Due to wedging action between the conical
working surfaces, there is considerable normal pressure and friction force with a small engaging force.
The semi cone angle is kept greater than a certain value to avoid self-engagement; otherwise
disengagement of clutch would be difficult. This is kept around 12.50.
 Cone clutch has become obsolete as a means of transferring power from the engine
to the gearbox. The power transfer is done through friction clutches/ torque converters.
 CLUTCH
Electromagnetic Clutch

Definition of Electromagnetic clutch

o Electromagnetic clutch is a cultch which uses the
Electro-magentic force to engage the dry friction
clutch instead of spring pressure.
o In this type of clutch, the flywheel consists of
winding. The current supplied in the winding from the
battery or dynamo.
 When the current passes through the winding, it
produces an electromagnetic field which attracts
the pressure plate, thereby engaging the clutch.
When the supply is cut-off, the clutch is
disengaged.
 CLUTCH
Electromagnetic Clutch
Construction & Working
The Driven Plate A has a hub which is splined to
output shaft B.
The Pressure Plate C is Bolted to Armature Disc D
which itself is secured to the flywheel.
The armature disc D is mag isolated from flywheel by
3 links F which also provide it small axial movement.
When the winding is energised in the armature D, the
Pressure Plate C is attracted to the flywheel so that
driven plate is squeezed between the Pressure plate &
member G which is rigidly bolted to flywheel at 3
points.
 CLUTCH
Vacuum Clutch
Definition of Vacuum Clutch
oIt consists of a vacuum cylinder with piston, solenoid operate
valve, reservoir and a non- return valve.
The reservoir is connected to the engine manifold through a non-
return valve.
Vacuum cylinder is connected to the reservoir through solenoid
operated valve.
The solenoid is operated form the battery and the circuit
incorporates a switch which is placed in the gear lever.
oMovement of the piston is transmitted by a linkage to the clutch,
causing it to disengage.
When the driver is not operating the gear lever, the switch is
open and the clutch remains engaged due to the force of springs.
 CLUTCH
Hydraulic Clutch

Definition of Hydraulic Clutch

oThe hydraulic clutch is operated in the same way as the vacuum clutch. Only the
difference is that it is operated by oil pressure whereas the vacuum clutch is
operated by vacuum.
The pump is operated by the engine itself. The oil from the reservoir is pumped
into the accumulator tank.
The accumulator tank is connected to the cylinder through the control valve. The
control valve is electrically controlled by a switch in the gear lever.
oWhen the driver holds the gear lever to change the gears, the switch is operated
to open the control valve admitting the oil under pressure to the cylinder.
Due to the oil pressure, the piston moves causing the clutch to the disengaged.
oAs soon as the driver leaves the gear lever, the switch is open which closed the
control valve and the clutch is engaged.