Clutch, Coupling and Brake

PREPARED BY: DHarmik Patel

Assistant Professor,
Mechanical Engineering Department,
GDEC Navsari
 Clutch, Coupling and Brake

Clutch

Function:

❖ A clutch connects and disconnects two rotating shafts, typically

the engine and the transmission in a vehicle.

❖ Allows for controlled engagement and disengagement of

power transmission.

Use case:

❖ Used in vehicles to change gears smoothly.

❖ Engages/disengages the engine from the drivetrain.

 Clutch, Coupling and Brake

Coupling
Function:
❖ A coupling permanently connects two shafts to transmit power
while accommodating minor misalignment.
❖ Unlike a clutch, it usually doesn't engage or disengage during
operation.
Use case:
❖ Used in machinery to join motor shafts to pump/compressor
shafts.
❖ Absorbs shock and vibration, and compensates for shaft
misalignment.
 Clutch, Coupling and Brake

Brake
Function:

❖ A brake is used to stop or slow down a rotating shaft.

❖ Converts kinetic energy into heat via friction.

Use case:

❖ Used in vehicles, elevators, industrial machinery.

❖ Essential for safety and motion control.

 Coupling

Rigid Coupling
Description: Connects two shafts that are perfectly aligned.
Types:
❖ Sleeve or Muff Coupling
❖ Clamp or Split Muff Coupling
❖ Flange Coupling
Applications:
❖ Low-speed, high-torque applications
❖ Lathes, conveyors, and pumps with precise shaft alignment
 Coupling

Flexible Coupling
Description: Allows some misalignment, absorbs shock and vibration.
Types:
❖ Bush Pin Coupling – uses rubber or leather bushings
❖ Oldham Coupling – has a middle disc to compensate for lateral misalignment
❖ Universal Joint (Hooke's Joint) – used for angular misalignment
Applications:
❖ Pumps, compressors, and motor-driven equipment
❖ Automobiles (drive shaft), CNC machinery
 Rigid Coupling

1. Sleeve or Muff Coupling

❖ A sleeve coupling, also known as a muff coupling, is a simple mechanical device used to connect
two shafts for power transmission.
❖ It consists of a hollow cylindrical sleeve that fits over the ends of two shafts, securing them
together.
❖ The key components include:
Sleeve: The central cylindrical part that connects the shafts.
Keys and Keyways: These ensure a secure fit and prevent slippage.
Fasteners: Bolts and nuts may be used for additional security.
 Rigid Coupling

1. Sleeve or Muff Coupling

 Rigid Coupling

1. Sleeve or Muff Coupling

 Rigid Coupling

1. Sleeve or Muff Coupling

❖ Sleeve couplings are commonly used in machinery where precise alignment isn't critical.
❖ They can accommodate minor misalignments and help reduce shock and vibration during
operation.
Advantages of Sleeve or Muff Coupling: Disadvantages of Muff Coupling:
❖ Simple Design: ❖ Rigid – No Flexibility:
❖ Low Cost: ❖ Difficult to Dismantle:
❖ Easy Maintenance: ❖ Not Suitable for High Torque:
❖ Good for Alignment: ❖ No Vibration Damping:
❖ Efficient Torque Transmission: ❖ Keyway Weakens Shafts:
❖ Reliable for Light and Medium Loads: ❖ Wear and Tear at the Key:
❖ Occupies Less Space:
 Rigid Coupling

2. Split Muff Coupling

❖ A split muff coupling is a modified version of the standard muff (sleeve) coupling.
❖ As the name suggests, the sleeve (muff) is split into two halves either horizontally or vertically,
and the two halves are bolted together around the shafts.
Construction:
❖ Two split halves of a sleeve (cast iron or mild steel).
❖ Bolts and nuts used to clamp the two halves together.
❖ Keys are used to transmit torque between the shaft and the sleeve.
 Rigid Coupling

2. Split Muff Coupling

Advantages of Split Muff Coupling: Disadvantages of Split Muff Coupling:

❖ Easy to Assemble and Disassemble: ❖ More Expensive:

❖ Quick Maintenance: ❖ Heavier Design:

❖ Saves Downtime: ❖ Risk of Misalignment:

❖ Stronger than Solid Muff: ❖ Bolt Loosening:

Applications:
❖ Used in industries where shaft disassembly is frequent.
❖ Common in pumps, compressors, and heavy-duty machinery where
maintenance access is critical.
 Rigid Coupling

3. Flange Coupling

❖ A flange coupling is a type of rigid coupling used to connect two shafts end-to-end for torque
transmission.
❖ It consists of two flanges (discs), one on each shaft, which are bolted together to form a solid,
rigid joint.

Construction:
❖ Two flanges—each keyed to the shaft ends.
❖ Flanges are bolted together with nuts and bolts.
❖ Keys fit into the keyways on the shaft and flange to transmit torque.
❖ The connection may include a gasket between the flanges (in some designs).
 Rigid Coupling

3. Flange Coupling
Types of Flange Couplings:
❖ Unprotected Type Flange Coupling:
Bolts are exposed—used where safety is not a concern.
❖ Protected Type Flange Coupling:
Bolts are covered for safety—commonly used in heavy
machinery.
 Rigid Coupling

Disadvantages of Flange Coupling:

3. Flange Coupling
❖ Requires Accurate Alignment:
Advantages of Flange Coupling: ❖ Not Suitable for Dynamic Loads Without Flexibility:
❖ Strong and Rigid: ❖ Heavier and Bulkier:
❖ Easy Assembly and Disassembly: ❖ Maintenance of Bolts:
❖ Reliable Connection:
❖ Customizable Designs:
Applications:
Heavy-duty applications like:
❖ Pumps
❖ Gearboxes
❖ Compressors
❖ Marine engines
 Flexible Coupling

1. Bush Pin Coupling

❖ A Bush Pin Coupling is a type of flexible coupling used to connect

two shafts while allowing for a small amount of misalignment,
shock absorption, and vibration damping.
❖ It's a popular choice where flexibility and reliability are both
needed.

Construction:
❖ Two flanges (similar to flange coupling), mounted on the shaft ends.
❖ Pins (bolts) connect the flanges together.
❖ Rubber or leather bushes are fitted over the pins, providing flexibility
and cushioning.
 Flexible Coupling

1. Bush Pin Coupling Applications:

Advantages of Bush Pin Coupling: ❖ Pumps

❖ Can Handle Small Misalignments: ❖ Compressors

❖ Shock Absorption: ❖ Conveyors

❖ Simple and Cost-Effective: ❖ Light to medium industrial

❖ Reduces Noise and Wear: machinery

❖ Low Maintenance:
Disadvantages of Bush Pin Coupling:
❖ Limited Flexibility:
❖ Bushing Wear Over Time:
❖ Not for High-Speed or Precision Applications:
❖ Heat Sensitivity:
 Flexible Coupling

2. Oldham Coupling

❖ The Oldham coupling is a flexible mechanical coupling designed to accommodate parallel

(lateral) misalignment between two shafts while transmitting torque.

Construction:
❖ Two hubs – one mounted on each shaft.
❖ Center disc (floating disk) – fits between the hubs and has slots on both sides.
❖ Each hub has a tongue (or key) that fits into the slots on either side of the center disc.
❖ The center disc can slide back and forth as the shafts rotate, allowing for misalignment
 Flexible Coupling

2. Oldham Coupling
 Flexible Coupling

2. Oldham Coupling

Advantages of Oldham Coupling: Disadvantages of Oldham Coupling:

❖ Excellent for Parallel Misalignment: ❖ Limited Angular or Axial Misalignment
❖ Simple Maintenance: ❖ Best for parallel misalignment, not ideal
❖ Smooth Torque Transmission: for angular or axial offsets.
❖ No Lubrication Required: ❖ Wear of Center Disc:
❖ Lower Torque Capacity:

Applications: ❖ Servo motors

❖ Robotics ❖ Light-duty precision
❖ CNC machines equipment
❖ Printers
 Flexible Coupling

3. Universal Coupling (Universal Joint or U-Joint)

❖ A Universal Coupling, commonly known as a Universal Joint (U-joint), is a mechanical device
that allows torque transmission between two shafts that are not in line and can be at a varying
angle to each other.

Construction:
❖ Consists of two yokes: One attached to each shaft.
❖ Connected by a cross (spider) at the center.
❖ The cross has four arms, each connected to a yoke via bearings or bushings.
❖ As one shaft rotates, the cross allows the other shaft to follow the motion even if it's at an angle.
 Flexible Coupling

3. Universal Coupling (Universal Joint or U-Joint)

 Flexible Coupling

3. Universal Coupling (Universal Joint or U-Joint)

Disadvantages of Universal Coupling:
Advantages of Universal Coupling:
❖ Non-Uniform Output Speed:
❖ Handles Angular Misalignment:
❖ Requires Lubrication:
❖ Simple and Compact:
❖ Vibration and Noise at High Speeds:
❖ Reliable Torque Transmission:
❖ Wear and Tear:
❖ Widely Used in Automotive Applications:
❖ Cost-Effective: Applications:
❖ Automotive drive shafts
❖ Steering columns
❖ Industrial machinery
❖ Textile and printing machines
❖ Aerospace mechanisms
Clutch
 Positive Clutch

Positive Clutch
❖ A Positive Clutch is a type of mechanical clutch that transmits torque by direct
mechanical interlocking between driving and driven parts.
❖ Unlike friction clutches, it does not rely on friction — instead, it uses projections
(dogs, teeth, or jaws) that fit into corresponding slots.
 Friction Clutch

Plate Clutch (Friction Plate Clutch)

❖ A Plate Clutch is a friction-type clutch used to transmit torque from a driving shaft (usually
connected to an engine) to a driven shaft. It is commonly found in automobiles, motorcycles, and
machinery where controlled power transmission is required.
Construction:
❖ Flywheel – mounted on the engine shaft.
❖ Clutch Plate (Friction Disc) – has friction linings on both sides and is mounted on the driven shaft.
❖ Pressure Plate – presses the clutch plate against the flywheel.
❖ Clutch Springs – provide the clamping force.
❖ Clutch Release System – lever, bearing, or pedal used to disengage the clutch.
When engaged, friction between the clutch plate and flywheel allows torque to transfer from engine to
transmission.
 Friction Clutch

Plate Clutch (Friction Plate Clutch)

 Friction Clutch

Plate Clutch (Friction Plate Clutch)

 Friction Clutch

Plate Clutch (Friction Plate Clutch)

Working Principle:
❖ Engaged Position: Springs push the clutch
plate tightly between the flywheel and
pressure plate, allowing torque to pass.
❖ Disengaged Position (when pedal is
pressed): The clutch plate is released,
breaking the connection and stopping
power flow—used for gear shifting or idling.
 Friction Clutch

Plate Clutch (Friction Plate Clutch)

Advantages of Plate Clutch: Disadvantages of Plate Clutch:
❖ Smooth Engagement: ❖ Friction Losses:
❖ Controlled Power Transmission: ❖ Wear and Tear:
❖ Easy to Operate: ❖ Heat Generation:
❖ Compact and Reliable: ❖ Not Ideal for Constant Torque Applications:

Applications:
❖ Automobiles (manual transmission)
❖ Motorcycles
❖ Heavy machinery
❖ Racing vehicles
❖ Industrial power drives
 Friction Clutch

Cone Clutch (Friction Plate Clutch)

❖ A Cone Clutch is a friction clutch that uses conical (cone-shaped) surfaces instead of flat ones to
transmit torque between two shafts.
❖ It operates on the same principle as a plate clutch but uses a cone for engagement, offering
greater frictional surface area.

Construction:
❖ Inner Cone (Male Cone) – connected to the driven shaft.
❖ Outer Cone (Female Cone or Cup) – attached to the driving shaft.
❖ Friction Lining – on the inner cone or both cones to improve grip.
❖ Spring Mechanism – holds the cones in contact.
❖ Lever or Pedal – used to disengage the clutch by pulling the cones apart.
 Friction Clutch

Cone Clutch (Friction Plate Clutch)

 Friction Clutch

Cone Clutch (Friction Plate Clutch)

Advantages of Cone Clutch:
Disadvantages of Cone Clutch:
❖ Greater Torque Transmission:
❖ Self-Locking Tendency:
❖ Less Axial Force Required:
❖ Wear Sensitivity:
❖ Compact Design:
❖ Alignment Issues:
❖ Smoother Engagement:
❖ Less Common Today:

Applications:
❖ Old automobiles and motorcycles (before plate clutches became standard)
❖ Marine engines
❖ Machine tools
❖ Low-speed applications where high torque is needed in a compact design
 Friction Clutch

Centrifugal (Friction Plate Clutch)

❖ A centrifugal clutch is an automatic friction clutch that engages or disengages based on engine
speed (RPM) using centrifugal force.
❖ It requires no manual operation, making it ideal for small engines and low-speed machines.

Construction:
❖ Driving Member (Drum): Connected to the engine shaft.
❖ Shoes or Pads: Mounted on the inner hub; equipped with friction linings.
❖ Springs: Keep the shoes retracted at low speeds.
❖ Driven Shaft: Connected to the outer drum or casing.
 Friction Clutch

Centrifugal (Friction Plate Clutch)

Working Principle:
At low speeds (idle):
❖ Springs hold the shoes inward, so no contact
with the drum — clutch is disengaged.
At higher speeds:
❖ Centrifugal force pushes the shoes outward,
pressing them against the drum.
❖ Friction between shoes and drum engages the
clutch, transmitting torque to the driven shaft.
 Friction Clutch

Centrifugal (Friction Plate Clutch)

 Friction Clutch

Centrifugal (Friction Plate Clutch)

Applications:
Advantages of Centrifugal Clutch:
❖ Scooters and mopeds
❖ Automatic Operation:
❖ Go-karts
❖ Smooth Engagement:
❖ Mini bikes
❖ Simple and Compact:
❖ Lawnmowers
❖ Protects Engine from Overload:
❖ Chainsaws
Disadvantages of Centrifugal Clutch: ❖ Small machinery
❖ Limited Torque Capacity:
❖ Slippage at High Loads:
❖ Wear of Shoes:
❖ Heat Generation:
 Brake

Shoe Brake (Brake Drum System) Applications of Shoe Brake

❖ Automotive Braking Systems: Especially in older vehicles
or on the rear wheels of modern cars.
❖ Industrial Machinery: Used in cranes, hoists, elevators,
and conveyors.
❖ Railways: Employed in braking systems for trains and
trams.
❖ Agricultural Equipment: Tractors and other farming
machines.
❖ Heavy-Duty Trucks and Trailers: Where strong braking
force is needed.
 Brake

Shoe Brake

A shoe brake is a type of friction brake where brake shoes press against a rotating drum
to slow or stop motion.
It's commonly found in drum braking systems in vehicles and industrial machinery.

Advantages of Shoe Brake Disadvantages of Shoe Brake

❖ Simple Design: ❖ Heat Dissipation Issues:
❖ Cost-Effective:. ❖ More Complex Adjustment:
❖ Self-Energizing Effect: ❖ Heavier and Bulkier:
❖ Good for Low-Speed Applications ❖ Less Responsive
❖ Enclosed System: ❖ Uneven Wear:
 Brake

Band Brake
Applications of Band Brake
❖ Winches and Hoists: For controlling
lowering or lifting loads.
❖ Conveyor Systems: To stop or control
material flow.
❖ Elevators: Emergency braking systems.
❖ Automotive (Historically): Older cars and
motorcycles (now largely obsolete in
vehicles).
❖ Industrial Machines: Tension control
systems in textile or paper processing
machines.
 Brake

Band Brake
A band brake is a type of brake where a flexible band (usually made of steel lined with friction
material) wraps around a rotating drum. When tension is applied to the band, it creates friction
and slows or stops the drum.

Advantages of Band Brake Disadvantages of Band Brake

❖ Simple Construction: Easy to design, ❖ Poor Heat Dissipation: Can overheat quickly under
install, and maintain. continuous or high-speed use.
❖ Compact and Lightweight: Requires less ❖ Friction Depends on Direction: Works best in one
direction of rotation (not ideal for bidirectional
space and is lighter than other brake types.
rotation).
❖ Cost-Effective: Inexpensive compared to
❖ Slippage Risk: If not properly adjusted, the band may
disc or drum brakes. slip, reducing braking effectiveness.
❖ High Torque Output: Capable of producing ❖ Uneven Wear: Band and drum may wear unevenly
a large braking torque with small effort. over time.
❖ Effective at Low Speeds: Performs well in ❖ Not Suitable for High-Speed Use: Performance drops
low-speed applications. at higher rotational speeds due to heat and wear.
 Brake

Internal Expanding Brake

 Brake

Internal Expanding Brake

Applications of Internal Expanding Brake
❖ Automobiles: Commonly used in rear wheels of many
cars and trucks.
❖ Motorcycles: Found in some drum-brake-equipped
models.
❖ Elevators and Hoists: Used for stopping and holding
mechanisms.
❖ Industrial Cranes: For load braking and holding.
❖ Agricultural Equipment: Tractors and small machinery
where compact braking systems are needed.
 Brake

Internal Expanding Brake

An internal expanding brake works by pressing brake shoes outward against the inner surface of a rotating
drum. This action creates friction that slows or stops the rotation. It’s commonly found in automotive and
industrial braking systems.

Advantages of Internal Expanding Brake Disadvantages of Internal Expanding Brake

❖ Protected Design: Being enclosed, the system is ❖ Heat Buildup: Poorer heat dissipation compared to
shielded from dust, dirt, and water. disc brakes, leading to brake fade under heavy or
❖ Compact Structure: Efficient use of space, prolonged use.
especially in automotive wheels. ❖ More Complex Mechanism: Involves springs,
❖ Self-Energizing Action: In leading shoe designs, adjusters, and linkages that can wear out or need
the drum rotation can help press the shoe harder tuning.
against the drum, increasing braking force. ❖ Non-uniform Wear: Brake shoes can wear unevenly,
❖ Good for Holding Loads: Excellent in applications requiring periodic adjustment or replacement.
like hoists or elevators where holding power is ❖ Slower Response: Not as quick to respond as disc
needed. brakes in high-speed conditions.
❖ Low Maintenance Frequency: Requires relatively ❖ Difficult Inspection: The enclosed design makes it
infrequent servicing in many systems. harder to visually inspect components.
 Brake

Disc Brake Applications of Disc Brakes

❖ Automobiles: Widely used in cars, especially in the
front wheels, and in high-performance vehicles for all
wheels.
❖ Motorcycles: Common in both front and rear wheels
due to better handling and performance.
❖ Bicycles: Found in mountain bikes and high-
performance road bikes for better control.
❖ Aircraft: Used in landing gear systems for effective
stopping after touchdown.
❖ Industrial Machinery: cranes, elevators, and other
heavy equipment where precise control is needed.
 Brake

Disc Brake
 Brake

Disc Brake
Advantages of Disc Brakes Disadvantages of Disc Brakes

❖ Better Heat Dissipation: Disc brakes cool down faster ❖ Higher Cost:

due to their open design, reducing the risk of brake ❖ More Complex Design: Hydraulic systems

fade. and components may be more complex to

❖ Improved Performance in Wet Conditions repair.

❖ More Stopping Power: provide better braking ❖ Pad Wear: Brake pads may wear out faster,

efficiency, especially under aggressive driving or riding

❖ Self-Cleaning: The open design helps remove debris, conditions.

dust, and water from the braking surface. ❖ No Parking Brake in Basic Systems: Some

❖ Quick and Easy Maintenance: Brake pads are easier disc brake systems need a separate

to inspect and replace. mechanism for parking brakes.

❖ Lighter and Compact: ❖ Potential for Warping: Excessive heat or

uneven torque can cause disc warping.