Design of Mechanical Transmission Systems

NPTEL | Week 11 – Assignment 11

SECTION A: Theory & Conceptual Questions

Q1. In a friction clutch, what is the purpose of the pressure plate? [1 point]

(a) Only to engage the clutch

(b) To transmit power to the transmission
✔ (c) To engage and disengage the clutch
(d) To provide lubrication

✔ Correct | Score: 1/1

Answer: (c) To engage and disengage the clutch

Explanation:
The pressure plate is a key component in a friction clutch assembly. It is pressed
against the friction disc by the spring force to engage the clutch (connect engine
to transmission). When the driver presses the clutch pedal, the spring force is
released, moving the pressure plate away and disengaging the clutch.

• Options (a) and (d) are too narrow / incorrect — lubrication is not its function.
• Option (b) is the role of the friction disc/lining, not the pressure plate directly.

Q2. Formula for effective friction radius (Rf) under Uniform Wear Theory? [1 point]

(a) Rf = (D+d)/4
(b) Rf = (R+r)/2
(c) Rf = (D+d)/8 [i.e., same as (R+r)/2 in radius notation]
✔ (d) Both (a) and (b)

✘ Incorrect | Score: 0/1

 Answer: (d) Both (a) and (b)

Explanation:
Under Uniform Wear Theory (for a worn-in clutch), the effective friction radius is:

Rf = (R + r) / 2 — using outer radius R and inner radius r

Converting to diameters (R = D/2, r = d/2):

Rf = (D/2 + d/2) / 2 = (D + d) / 4

So BOTH expressions (a) and (b) represent the SAME formula. Hence answer is (d).

NOTE: This student initially chose option (a) alone and scored 0.
The correct accepted answer was 'Both (a) and (b)'.

Q3. Which wear mechanism needs to be applied if the clutch is new? [1 point]

✔ (a) Only uniform pressure theory

(b) Only uniform wear theory
(c) Both should be applied
(d) Neither of the above

✔ Correct | Score: 1/1

Answer: (a) Only Uniform Pressure Theory

Explanation:
Two design theories exist for friction clutches:

• Uniform Pressure Theory: Assumes constant pressure distribution across the

friction surface. Applies to a NEW clutch where surfaces are perfectly flat
and the spring force is uniformly distributed.

• Uniform Wear Theory: Assumes that wear is uniform (product p × r = constant).

This applies to a WORN-IN (old/used) clutch where surfaces have conformed.

For a NEW clutch → Uniform Pressure Theory is used.

For an OLD/WORN clutch → Uniform Wear Theory is used.

Q4. The purpose of the friction material in a clutch is to: [1 point]

 (a) Increase the heat dissipation
(b) Reduce the engagement force
(c) Reduce the heat dissipation
✔ (d) Enhance the torque transmission

✔ Correct | Score: 1/1

Answer: (d) Enhance the torque transmission

Explanation:
The friction lining material (e.g., asbestos, ceramic, organic compounds) has a
high coefficient of friction (μ). The torque transmitted by a clutch is:

T = μ × W × Rf × n
where μ = coeff. of friction, W = axial force, Rf = effective radius, n = surfaces

A higher μ means more torque for the same axial force. Hence, the friction material
ENHANCES the torque transmission capacity of the clutch.

SECTION B: Single Dry Plate Clutch Design Problem

Given Data:
• Power (P) = 7.5 kW = 7500 W
• Speed (N) = 900 rpm
• Ratio of mean radius to width: Rm/b = 4 (i.e., Rm = 4b)
• Theory: Uniform Wear
• Allowable pressure (p_max) = 0.07 MPa = 0.07 N/mm²
• Coefficient of friction (μ) = 0.25
• Single dry plate clutch with BOTH sides friction lining → n = 2 surfaces

Q5. Find the torque transmitted to clutch in N·m [2 points]

Step 1: Calculate angular velocity (ω)

ω = 2πN/60 = 2π × 900/60 = 94.25 rad/s
Step 2: Calculate torque from power
T = P/ω = 7500/94.25 = 79.58 N·m

✔ Correct | Score: 2/2

 Answer: T = 79.58 N·m

Formula: T = P/ω = P × 60 / (2πN)

T = 7500 × 60 / (2π × 900) = 450000 / 5654.87 ≈ 79.58 N·m

Q6. Find the diameter (mm) of the clutch shaft if allowable shear stress = 40 MPa [1 point]

Step 1: Use torsion formula

T = (π/16) × τ × d³
Step 2: Rearrange for diameter
d³ = 16T / (π × τ)
Step 3: Substitute values
d³ = (16 × 79.58) / (π × 40) = 1273.28 / 125.66 = 10.133 × 10³ mm³
Step 4: Solve for d
d = ∛10133 = 21.67 mm

✔ Correct | Score: 1/1

Answer: d = 21.67 mm (Accepted range: 19–23 mm)

Formula: d = ∛(16T / πτ)

d = ∛(16 × 79580 N·mm / (π × 40 N/mm²))
d = ∛(10133.7) ≈ 21.67 mm

Note: T must be in N·mm when τ is in N/mm². Convert: 79.58 N·m = 79580 N·mm

Q7. Width of the friction lining in mm [1 point]

For Uniform Wear Theory:

• Effective radius: Rm = (R + r)/2 = (Ro + Ri)/2
• Width of lining: b = Ro - Ri
• Given: Rm/b = 4 → Rm = 4b
• Axial force: W = 2π × p_max × r × (R - r) = 2π × p_max × Ri × b
• Torque: T = μ × W × Rm × n (n = 2 for both sides)

Step 1: Express Ri and Ro in terms of b

Rm = 4b → (Ro + Ri)/2 = 4b → Ro + Ri = 8b Also: Ro - Ri = b → Ro = Ri + b Substituting: (Ri + b) + Ri =
8b → 2Ri = 7b → Ri = 3.5b Therefore: Ro = 4.5b
Step 2: Find axial force W
W = 2π × p_max × Ri × b = 2π × 0.07 × 3.5b × b = 1.539b² N (b in mm)
Step 3: Apply torque equation
T = μ × W × Rm × n 79580 = 0.25 × 1.539b² × 4b × 2 79580 = 3.078b³
Step 4: Solve for b
b³ = 79580 / 3.078 = 25855 b = ∛25855 ≈ 29.6 ≈ 30 mm

✔ Correct | Score: 1/1

Answer: b = 30 mm (Accepted range: 28–32 mm)

Using: T = μ × 2π × p_max × Ri × b × Rm × n
With Ri = 3.5b, Rm = 4b, n = 2:
79580 = 0.25 × 2π × 0.07 × 3.5b × b × 4b × 2
b³ = 25855 → b ≈ 30 mm

Q8. Inner radius of the clutch plate in mm [1 point]

Step 1: Use relation found above

Ri = 3.5b = 3.5 × 30 = 105 mm
Step 2: Verify in range
Accepted range: 102–104 mm. With b = 29.6 mm → Ri = 3.5 × 29.6 = 103.5 mm ✔

✔ Correct | Score: 1/1

Answer: Ri = 103.5 mm (Accepted range: 102–104 mm)

Using exact b = 29.6 mm: Ri = 3.5 × 29.6 = 103.5 mm

With rounded b = 30 mm: Ri = 3.5 × 30 = 105 mm (slightly outside range).
Always use unrounded intermediate values for precision.

Q9. Outer radius of the clutch plate in mm [1 point]

Step 1: Use Ro = 4.5b

Ro = 4.5 × b = 4.5 × 29.6 = 133.1 mm

✔ Correct | Score: 1/1

Answer: Ro = 133.1 mm (Accepted range: 132–135 mm)

Ro = 4.5 × b → 4.5 × 29.6 = 133.1 mm ✔

SECTION C: Cone Clutch Problem
Given Data (Cone Clutch):
• Semi-cone angle (α) = 15°
• Operating load (W) = 45 kN = 45000 N
• Coefficient of friction (μ) = 0.30
• Ratio of inner to outer diameter: d/D = 0.5
• Outer diameter (D) = 0.4 m → Outer radius (R) = 0.2 m
• Inner radius: r = 0.5 × R = 0.1 m

Q10. Find the inner radius of the clutch in m [1 point]

Step 1: Given ratio d/D = 0.5

d/D = 0.5 → r/R = 0.5
Step 2: Outer radius R = D/2
R = 0.4/2 = 0.2 m
Step 3: Inner radius r
r = 0.5 × R = 0.5 × 0.2 = 0.1 m

✔ Correct | Score: 1/1

Answer: r = 0.1 m ✔

Inner diameter d = 0.5 × D = 0.5 × 0.4 = 0.2 m

Inner radius r = d/2 = 0.1 m

Q11. Torque by Uniform Pressure Theory in kN·m [1 point]

Q12. Torque by Uniform Wear Theory in kN·m [2 points]

Uniform Wear Theory for Cone Clutch:

T = μ × W × (R + r) / (2 × sin α)

Here, effective radius Rm = (R + r)/2 (same as flat clutch)

Step 1: Calculate mean radius Rm

Rm = (R + r)/2 = (0.2 + 0.1)/2 = 0.15 m
Step 2: Apply cone clutch torque formula
T = μ × W × Rm / sin α T = 0.30 × 45000 × 0.15 / sin 15° T = 2025 / 0.2588 T = 7824 N·m ≈ 7.82 kN·m

✔ Correct | Score: 2/2

Answer: T = 7.82 kN·m (Accepted range: 7.5–8.0 kN·m) ✔

T = μ × W × (R + r) / (2 × sinα)
T = 0.30 × 45000 × (0.2 + 0.1) / (2 × 0.2588)
T = 4050 / 0.5176 = 7824 N·m = 7.82 kN·m

SECTION D: Conceptual MCQs (Q13–Q17)

Q13. Disadvantage of single-plate clutches compared to multi-plate clutches? [1 point]

(a) Higher torque transmission capacity

(b) Smaller size and lighter weight
✔ (c) Lower durability under heavy loads
(d) Higher cost and complexity

✔ Correct | Score: 1/1

Answer: (c) Lower durability under heavy loads

Explanation:
Single plate clutches have only one friction surface per side (2 total).
Multi-plate clutches have multiple friction discs, distributing load over more
surfaces. This gives multi-plate clutches much higher torque capacity and
better durability under heavy load conditions.
Single-plate clutches are simple and cheaper, but they wear faster under
heavy-duty applications.
Q14. Which factor primarily determines the torque capacity of a multi-plate clutch? [1
point]

(a) Diameter of the friction discs

✔ (b) Number of friction discs
(c) Material of the friction discs
(d) Surface roughness of the friction discs

✔ Correct | Score: 1/1

Answer: (b) Number of friction discs

Explanation:
For a multi-plate clutch, torque T = μ × W × Rm × n
where n = number of effective friction surfaces.

Increasing the number of discs directly multiplies the torque capacity.

This is the primary advantage of multi-plate clutches — compact size with
high torque by stacking more discs.

Q15. Cone clutches are known for their ability to provide: [1 point]

(a) Rapid gear changes

(b) Variable torque transmission
(c) High-speed operation
✔ (d) Progressive engagement

✔ Correct | Score: 1/1

Answer: (d) Progressive engagement

Explanation:
Cone clutches use a conical mating surface. As the cone seats into its mating
surface, the normal force builds up gradually (unlike sudden snap engagement).
This provides PROGRESSIVE (smooth, gradual) engagement, which:
• Reduces shock loads on the drivetrain
• Gives the driver feel and control
• Is useful in machine tools and synchronizers

The wedging action of the cone also amplifies the normal force relative to axial
force (by 1/sinα), giving high torque capacity from a small actuation force.
Q16. Which statement about dry plate clutches is true? [1 point]

(a) They provide smoother engagement than wet plate clutches

✔ (b) They require regular maintenance to prevent overheating
(c) They are commonly used in automatic transmissions
(d) They are less efficient in transmitting torque compared to wet plate clutches

✔ Correct | Score: 1/1

Answer: (b) They require regular maintenance to prevent overheating

Explanation:
Dry clutches operate WITHOUT lubricant. This means:
• Higher coefficient of friction (good for torque transmission)
• No oil to carry away heat → they are prone to OVERHEATING
• Regular inspection and maintenance is needed
• They are typically used in manual transmissions (cars, motorcycles)

Wet clutches (used in automatic transmissions, motorbike wet clutches) are

bathed in oil — smoother engagement, better cooling, but lower μ.

Q17. Wet plate clutches are more susceptible to: [1 point]

✔ (a) Slippage
(b) Contamination
(c) Wear
(d) Overheating