Machine Component Design EMD223 Machine Component Design Dr. Mohamad Yusof Idroas Email: meyusof@eng.usm.my Room: 3.10 (SoME)

31/5: Final report submission EMD223 Important Dates Test #2 23 May 2012 (Wed) 8.30am-11am Project #2 30/5-31/5: Presentation 31/5: Final report submission

PROJECT #2 Each group must submit the log book by 11 May 2012 (Fri) At least to have final project title, application(s) and design structure. And tasks distribution among group members.

Consultation Slot EMD223 & SHE101 11 May 2012 Friday 11am -12.30pm 3pm – 4pm

Draft report submission Final report submission SHE101 Important Dates Draft report submission 21 May 2012 Final report submission 28 May 2012

EMD101 Urgent & Important The following names, please meet Mr. Solehuddin TODAY (10 May 2012): 1. Abdul Aziz Ansori bin Ismail 108125 2. Tiong Kwong Yii 108131 3. Effendy 108168 4. Chan Yaw Tsong 108132 5. Hamidah binti Sulfan Syah 108139 6. Wan Muhadziratul Ainaa 108171 7. Pathmaprasad 108165

Clutches, Brakes & Flywheels

Introduction CONE CLUTCHES A cone clutch is a type of clutch that utilizes a conical friction surface which meshes into a conical flywheel, wedging itself into a locked position. The act of the cone clutch wedging into the cone-shaped flywheel produces a much stronger lock up than that of a flat clutch and a flat flywheel. Used in early automobiles, the cone clutch is now found mainly in high-performance racing applications as well as off-shore racing boats. Main advantage: the clutch pedal does not need to be depressed completely in order to shift the transmission. Unlike a typical flat clutch system that requires complete pedal depression in order to release the clutch from the flywheel, the cone clutch requires only partial depression to break the friction bond of the clutch and allow easy shifting. What is jiggering process? Jiggering is a motion in which the clay bat is formed by means of templates or rollers. The jiggering process is limited to axisymmetric parts and has limited dimensional accuracy. Automation of this process is necessary to improve productivity. The layered structure of clay can be formed with anisotropic behavior of the material both in subsequent processing and in the final properties of the ceramic products What is anisotropy? What is anisotropic behavior?

Figure 1(a): A cone clutch Introduction CONE CLUTCHES Similar to disk clutch BUT friction interface for cone clutch is N = 1 and with cone angle, α varies up to 90o. It is impractical to have more than 1 friction interface for cone clutch. Figure 1(a): A cone clutch What is jiggering process? Jiggering is a motion in which the clay bat is formed by means of templates or rollers. The jiggering process is limited to axisymmetric parts and has limited dimensional accuracy. Automation of this process is necessary to improve productivity. The layered structure of clay can be formed with anisotropic behavior of the material both in subsequent processing and in the final properties of the ceramic products What is anisotropy? What is anisotropic behavior?

Design Analysis Based on Figure 1(b), few important design equations are derived as follow: Surface area of a ring element: What is jiggering process? Jiggering is a motion in which the clay bat is formed by means of templates or rollers. The jiggering process is limited to axisymmetric parts and has limited dimensional accuracy. Automation of this process is necessary to improve productivity. The layered structure of clay can be formed with anisotropic behavior of the material both in subsequent processing and in the final properties of the ceramic products What is anisotropy? What is anisotropic behavior?

Design Analysis Normal force on the element: Corresponding clamping force: Torque transmitted by the element: What is jiggering process? Jiggering is a motion in which the clay bat is formed by means of templates or rollers. The jiggering process is limited to axisymmetric parts and has limited dimensional accuracy. Automation of this process is necessary to improve productivity. The layered structure of clay can be formed with anisotropic behavior of the material both in subsequent processing and in the final properties of the ceramic products What is anisotropy? What is anisotropic behavior?

Design Analysis Equations for clamping force & torque capacity for a cone clutch are DERIVED EXACTLY as for a disk clutch BUT with a consideration of cone angle: Case 1: Uniform pressure & N = 1 Case 2: Uniform wear rate & N = 1 What is jiggering process? Jiggering is a motion in which the clay bat is formed by means of templates or rollers. The jiggering process is limited to axisymmetric parts and has limited dimensional accuracy. Automation of this process is necessary to improve productivity. The layered structure of clay can be formed with anisotropic behavior of the material both in subsequent processing and in the final properties of the ceramic products What is anisotropy? What is anisotropic behavior?

Design Analysis EFFECTS OF CONE ANGLE (α): SMALLER the cone angle, LESS clamping force required. But the cone angle cannot be smaller than about 8o due to: (i) Cone clutch tends to "grab" when engaged. (ii) Cone clutch tend to be difficult to disengage. Accepted & practical range is between 8o and 15o Optimum cone angle is 12o What is jiggering process? Jiggering is a motion in which the clay bat is formed by means of templates or rollers. The jiggering process is limited to axisymmetric parts and has limited dimensional accuracy. Automation of this process is necessary to improve productivity. The layered structure of clay can be formed with anisotropic behavior of the material both in subsequent processing and in the final properties of the ceramic products What is anisotropy? What is anisotropic behavior?

Introduction DRUM BRAKES TWO types of drum brakes (work mechanism): 1. Drum brakes with external shoes that contract to bear against the outer (cylindrical) drum surface. 2. Drum brakes with internal shoes that expand to contact the inner drum surface TWO types of shoes for drum brake: 1. "Short Shoe" - a shoe that contacts only a SMALL SEGMENT of the drum periphery 2. "Long Shoe" - a shoe that contacts the drum OVER AN ARC of about 45o or more What is jiggering process? Jiggering is a motion in which the clay bat is formed by means of templates or rollers. The jiggering process is limited to axisymmetric parts and has limited dimensional accuracy. Automation of this process is necessary to improve productivity. The layered structure of clay can be formed with anisotropic behavior of the material both in subsequent processing and in the final properties of the ceramic products What is anisotropy? What is anisotropic behavior?

Introduction Figure 2: “Short-shoe” drum brake What is jiggering process? Jiggering is a motion in which the clay bat is formed by means of templates or rollers. The jiggering process is limited to axisymmetric parts and has limited dimensional accuracy. Automation of this process is necessary to improve productivity. The layered structure of clay can be formed with anisotropic behavior of the material both in subsequent processing and in the final properties of the ceramic products What is anisotropy? What is anisotropic behavior?

Figure 3: External “long-shoe” drum brake Introduction Figure 3: External “long-shoe” drum brake What is jiggering process? Jiggering is a motion in which the clay bat is formed by means of templates or rollers. The jiggering process is limited to axisymmetric parts and has limited dimensional accuracy. Automation of this process is necessary to improve productivity. The layered structure of clay can be formed with anisotropic behavior of the material both in subsequent processing and in the final properties of the ceramic products What is anisotropy? What is anisotropic behavior?

Figure 4: Internal “long-shoe” drum brake Introduction Figure 4: Internal “long-shoe” drum brake What is jiggering process? Jiggering is a motion in which the clay bat is formed by means of templates or rollers. The jiggering process is limited to axisymmetric parts and has limited dimensional accuracy. Automation of this process is necessary to improve productivity. The layered structure of clay can be formed with anisotropic behavior of the material both in subsequent processing and in the final properties of the ceramic products What is anisotropy? What is anisotropic behavior?

Design Analysis SHORT-SHOE DRUM BRAKES Based on Figure 2, design equations for a short-shoe drum brake are as follow: Self-energizing: the applied force (F) in applying the brake is assisted by the moment of the friction force (fNa) in clockwise drum rotation. What is jiggering process? Jiggering is a motion in which the clay bat is formed by means of templates or rollers. The jiggering process is limited to axisymmetric parts and has limited dimensional accuracy. Automation of this process is necessary to improve productivity. The layered structure of clay can be formed with anisotropic behavior of the material both in subsequent processing and in the final properties of the ceramic products What is anisotropy? What is anisotropic behavior?

Design Analysis SHORT-SHOE DRUM BRAKES Self-deenergizing: the application of brake is opposed at the reversed direction of friction force and counter-clockwise drum rotation. Self-locking: the shoe is brought in contact with the drum (with F = 0) for the drum to be locked against rotation in one direction. Based on Figure 2(d), self-locking is expressed as: What is jiggering process? Jiggering is a motion in which the clay bat is formed by means of templates or rollers. The jiggering process is limited to axisymmetric parts and has limited dimensional accuracy. Automation of this process is necessary to improve productivity. The layered structure of clay can be formed with anisotropic behavior of the material both in subsequent processing and in the final properties of the ceramic products What is anisotropy? What is anisotropic behavior?

Group Exercise Free Body Diagram (FBD): What is jiggering process? Jiggering is a motion in which the clay bat is formed by means of templates or rollers. The jiggering process is limited to axisymmetric parts and has limited dimensional accuracy. Automation of this process is necessary to improve productivity. The layered structure of clay can be formed with anisotropic behavior of the material both in subsequent processing and in the final properties of the ceramic products What is anisotropy? What is anisotropic behavior?

Group Exercise Summation of Moment at Origin: What is jiggering process? Jiggering is a motion in which the clay bat is formed by means of templates or rollers. The jiggering process is limited to axisymmetric parts and has limited dimensional accuracy. Automation of this process is necessary to improve productivity. The layered structure of clay can be formed with anisotropic behavior of the material both in subsequent processing and in the final properties of the ceramic products What is anisotropy? What is anisotropic behavior?

Thank You