Kom Unit-V

KOM
Unit V: Friction in Machine Element

UNIT V FRICTION IN MACHINE ELEMENTS
Surface contacts-Sliding and Rolling friction-Friction drives-Friction in screw
threads-Bearings and lubrication-Friction clutches-Belt and Rope drives-Friction in
brakes-Band and Block brakes.
FRICTION
When a body slides over another, the motion is resisted by a force called the
force of friction.
In lathe slides and journal bearings power transmitted reduced due to friction. In
such case, the friction reduced by lubricated surface.
Attempts are made to increase friction where the power is transmitted through
friction. Examples are friction clutches, belt drives, etc.
Even the tightness of nut and bolt is dependent mainly on the force of friction.
LAWS OF FRICTION
Experiments have shown that the force of solid friction
is directly proportional to normal reaction between the two surfaces
opposes the motion between the surfaces
depends upon the materials of the two surfaces
is independent of the area of contact
is independent of the velocity of sliding.
The last of these laws is not true in the strict sense as it has been found that the
friction force decreases slightly with the increase in velocity.
KINDS OF FRICTION
Usually, three kinds of friction, depending upon the conditions of surface considered.
1. Dry Friction
Dry friction is said to occur when there is relative motion between two
completely unlubricated surfaces. It is further divided into two types:
(a) Solid Friction
When the two surfaces have a sliding motion relative to each other, it is called
a solid friction.
(b) Rolling Friction
Friction due to rolling of one surface over another (e.g. ball and roller bearings)
is called rolling friction.
2. Skin or greasy friction:
When the two surfaces in contact have a minute thin layer of lubricant between
them, it is known as skin or greasy friction. Higher spots on the surface break
through the lubricant and come in contact with the other surface.
Department of Mechanical, AAMEC
Skin friction is also termed as boundary friction.

3. Film friction:
When the two surfaces in contact are completely separated by a lubricant,
friction will occur due to the shearing of different layers of the lubricant. This is
known as film friction or viscous friction.
FRICTION CLUTCHES:
A Clutch is a device used to transmit the rotary motion of one shaft to another
when desired. The axes of the two shafts are coincident.
1. Single plate (or) Disc clutch
2. Multi-plate clutch
3. Cone clutch
4. Centrifugal clutch
1. Single plate (or) Disc clutch:
A disc clutch consists of a clutch
plate attached to a splined hub which
is free to slide axially on splines cut
on the driven shaft.
The clutch plate is made of steel
and has a ring of friction lining on
each side. The engine shaft supports
a rigidly fixed flywheel.
A spring-loaded pressure plate
presses the clutch plate firmly against
the flywheel when the clutch is
engaged.
When disengaged, the springs pressed against a cover attached to the flywheel.
Thus, both the flywheel and the pressure plate rotate with the input shaft. The
movement of the clutch pedal is transferred to the pressure plate through a thrust
bearing.
Figure shows the pressure plate pulled back by the release levers and the friction
linings on the clutch plate are no longer in contact with the pressure plate or the
flywheel. The flywheel rotates without driving the clutch plate and thus, the driven
shaft.
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When the foot is taken off the clutch pedal, the pressure on the thrust bearing is
released. As a result, the springs become free to move the pressure plate to bring it in
contact with the clutch plate.
The clutch plate slides on the splined hub and is tightly gripped between the
pressure plate and the flywheel.
The friction between the linings on the clutch plate, and the flywheel on one side
and the pressure plate on the other, cause the clutch plate and hence, the driven shaft
to rotate.
3. Cone clutch:
In a cone clutch as shown in

figure, the contact surfaces are in the
form of cones.
In engaged position, the friction
surfaces of the two cones A and B are
in complete contact due to spring
pressure that keeps one cone pressed
against other all the time.
2. Multi-plate clutch:
In a multi-plate clutch, the number of frictional linings and the metal plates is
increased which increases the capacity of the clutch to transmit torque. Figure shows
a simplified diagram of a multi-plate clutch.
When the clutch is engaged, the torque is transmitted from the driving shaft to the
driven shaft through the flywheel and the friction cones. For disengaging the clutch,
the cone B is pulled back through a lever system against the force of the spring.
The advantage of a cone clutch is that the normal force on the contact surfaces is
higher than other types of clutches
4. Centrifugal clutch:
The friction rings are splined on their outer circumference and engage with
corresponding splines on the flywheel. They are free to slide axially. The friction
material thus, rotates with the flywheel and the engine shaft. The number of friction
rings depends upon the torque to be transmitted.
The driven shaft also supports discs on the splines which rotate with the driven
shaft and can slide axially. If the actuating force on the pedal is removed, a spring
presses the discs into contact with the friction rings and the torque is transmitted
between the engine shaft and the driven shaft.
If n is the total number of plates both on the driving and the driven members, the
number of active surfaces will be n - 1.
Centrifugal clutches are being increasingly used in automobiles and machines.

A centrifugal clutch has a driving member consisting of four sliding blocks as shown
in figure.
These blocks are kept in position by means of flat springs provided for the
purpose. As the speed of the shaft increases, the centrifugal force on the shoes
increases.
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When the centrifugal force exceeds the resisting force of the springs, the shoes
move forward and press against the inside of the rim and thus, torque is transmitted
to the rim. In this way, the clutch is engaged only when the motor gains sufficient
speed to take up the load in an effective manner. The outer surfaces of the shoes are
lined with some friction material.
Single plate clutch:
n1 - No. of discs on the driving shaft

n2 - No. of discs on the driven shaft
Uniform wear theory:
p.r = Constant = C
Max.pressure at inner radius = pmax.r1 = C
Min.pressure at outer radius = pmin.r2 = C
Average pressure p
W
2 r1 r2
W
r12
r22
Torque T = nWR
Mean radius R
r1 r2
2
Power P = T.
Torque T = I.
Angular acceleration = / t
p Intensity of pressure
r1 Outer radius
r2 Inner radius
W Axial thrust acting on the clutch plate
n Number of effective sides of plate
T Frictional Torque
Coefficient of friction between the surface
Uniform pressure theory:
Intensity of pressure p
Torque T = nWR
Mean radius R
2 r13 r23
3 r12 r22
r12
r22
For Single plate clutch

n=1 for one side effective
n=2 for both sides effective
For Multi-plate clutch
n=n1+n2-1
During slipping
Angle turned by the driving shaft 1 = t
Angle turned by the driven shaft 2 2 0 t
1 2
t
2
Energy lost due to friction = T(1- 2)

For New clutch Uniform pressure theory
For Old clutch Uniform wear theory
1. A single plate clutch both sides effective, has outer and inner diameters
300mm and 200mm respectively. The maximum intensity of pressure at any
point in the contact surface is not to exceed 0.1N/mm 2. If the coefficient of
friction is 0.3, determine the power transmitted by a clutch at a speed 2500rpm
for two types of assumptions, that is, for uniform pressure and uniform wear.
Given:
Single plate clutch
Both sides effective
Outer diameter of clutch plate d1 = 300 mm
Outer radius r1= 150mm
Inner diameter of clutch plate d2 = 200 mm
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Inner radius r2 =100mm
Maximum intensity of pressure pmax = 0.1 N/mm2
Coffecient of friction = 0.3
Speed N = 2500 r.p.m.
To find:
Power transmitted by a clutch at a speed 2500rpm for two types of assumptions
(i) For uniform pressure and
(ii) For uniform wear
Solution:
1. Uniform wear theory
Power transmitted by a clutch, P = T.
Torque transmitted, T = n..W.R
n = 2,for both sides of plate effective
=0.3 (cofficient of friction)
Axial thrust, W = 2 C (r1 r2)
Intensity of pressure (p) is maximum at the inner radius (r2) for uniform wear,
pmax.r2 = C
C = 0.1 100 = 10 N/mm
W = 2 C (r1 r2 ) = 2 10 (150 100) = 3142 N
Mean radius of the friction surfaces for uniform wear,
Mean radius R
r1 r2
2
150 100
= 125mm = 0.125m
2
Torque transmitted,
T = n..W.R = 2 0.3 3142 0.125 = 235.65 N-m
Angular velocity ()
2N
2 2500
= 261.8 rad/s
60
60
Power transmitted by a clutch,
P = T. = 235.65 261.8= 61 693 = 61.693 kW
2. Uniform pressure theory
Power P = T.
Torque T = nWR
n = 2, for both sides of plate effective
Axial thrust same for both uniform pressure and uniform wear theory
Therefore, W = 3142 N
2 r13 r23
2 150 3 100 3
Mean radius R
3 150 2 100 2
3 r12 r22
R = 126.67 mm =0.127m
Torque transmitted,
T = n..W.R = 2 0.3 3142 0.127 = 239.42 N-m
Angular velocity ()
2N
2 2500
= 261.8 rad/s
60
60
P = T. = 239.42 261.8 = 62680.26 = 62.68 kW
2. A friction clutch is used to rotate a machine from a shaft rotating at a uniform
speed of 250rpm. The disc-type clutch has both of its sides effective, the
coefficient of friction being 0.3. The outer and the inner diameters of the friction
plate are 200 mm and 120 mm respectively. Assuming uniform wear of the
clutch, the intensity of pressure is not more than 100 kN/m 2. If the moment of
inertia of the rotating parts of the machine is 6.5 kg-m 2. Determine the time to
attain the full speed by the machine and the energy lost in slipping of the clutch.
What will be the intensity of pressure if the condition of uniform pressure of the
clutch is considered? Also, determine the ratio of power transmitted with
uniform wear to that of uniform pressure.
Given:
Speed N =250 rpm
Disc type clutch (Single plate clutch)
Both sides effective, n=2
cofficient of friction =0.3
Outer diameter d1= 200 mm
Outer radius r1=100mm=0.1m
Inner diameter d2 = 120mm
Inner radius r2 = 60 mm=0.06m
Uniform wear
Max.intensity of pressure pmax= 100 kN/m2
Moment of inertia of rotating parts I= 6.5 kg-m2
To find:
(i)
Time to attain the full speed by the machine and
(ii)
Energy lost in slipping of the clutch
(iii)
Intensity of pressure for uniform pressure condition
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(iv)
Ratio of Power transmitted with uniform wear to that of uniform pressure
Solution:
(i)
Time to attain the full speed by the machine
Angular velocity
Angular acceleration
2N
2 250
Angular velocity
60
60
= 26.18 rad/s
T Torque transmitted
I
Moment of inertia
Torque transmitted, T = n..W.R
Axial thrust, W = 2 C (r1 r2)
Intensity of pressure (p) is maximum at the inner radius (r2) for uniform wear,
pmax.r2 = C
C = 100 103 0.06 = 6000 N/m
W = 2 C (r1 r2 ) = 2 6000 (0.1 0.06) = 1507.96 N
Mean radius of the friction surfaces for uniform wear,
Mean radius R
r1 r2
100 60
= 80 mm=0.08m
2
2
Torque transmitted, T = n..W.R = 2 0.3 1507.96 0.08 = 72.38 N-m

T
72.38
11.135 rad/s
I
6.5
26.18
t
2.35 sec
11.135
(ii) Energy lost in slipping of the clutch
Energy lost in friction = T (1-2)
Angle turned by the driving shaft 1 = t
2N
2 250
= 26.18 rad/s
60
60
1 = t =26.182.35 = 61.5 rad

Angle turned by the driven shaft 2
1
1
2
2 0 t t 2 0 2.35 11.135 2.35 = 30.75 rad
2
2
Energy lost in friction = T (1-2) = 72.38 (61.5-30.75) = 2226 N-m = 2.226 kN-m
(iii) Intensity of pressure for uniform pressure condition
W
r12
r22
Therefore, W = 1507.96 N
1507.96
0.12 0.006 2
p = 75000 N/m2 = 75 kN/m2
(iv) Ratio of Power transmitted with uniform wear to that of uniform pressure
Power transmitted P = T
For Uniform wear
T = 72.38 N-m
= 26.18 rad/s
Power transmitted for uniform wear
P = 72.3826.18 =1894.9 W
For Uniform Pressure
Torque T = nWR
Therefore, W = 1507.96 N
Mean radius R
2 r13 r23
2 0.13 0.06 3
3 0.12 0.06 2
3 r12 r22
R=0.0816m
Torque transmitted,
T = n..W.R = 2 0.3 1507.96 0.0816 =73.89 N-m
Angular velocity ()
2N
2 250
= 26.18 rad/s
60
60
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P = T. = 73.89 26.18 = 1934.44 W
Power with uniform wear
1894.9
=0.98
Power with uniform pressure 1934.44
= 212800(0.1143-0.08)
W = 2758.57 N
Mean radius R
r1 r2
0.1143 0.08
2
2
R = 0.09715 m
3. A friction clutch of multi-plate type is meant for transmitting a power of 55
kW at 1800 rpm. Coefficient of friction for the friction surfaces is 0.1. Axial
intensity of pressure is not to exceed 160 kN/m2. The internal radius is 80 mm
and is 0.7 times the external radius. Determine the number of plates needed to
transmit the required torque.
Given:
Maximum pressure pmax=160103 N/m2
Inner radius r2=80mm= 0.08m
Outer radius r1=0.08/0.7=0.1143m
Coefficient of friction =0.1
Speed N =1800 rpm
Power P =55kW
To find:
Number of plates needed to transmit the required torque.
Solution:
Number of plates required
n
Total torque tranmitted

Torque tranmitted by one plate
Total torque transmitted T = P/

2N
2 1800
= 188.5 rad/s
60
60
Total torque transmitted T = P/
=55103/188.5
=291.78 N-m
Torque transmitted by one plate T = WR
Assuming uniform wear condition
W = 2 C (r1 r2 )
pmin r1 = pmax.r2 = C
C = pmax.r2
= 160 103 0.08
= 12800 N/m
W = 2 C (r1 r2 )
Torque transmitted by one plate

T = WR
= 0.12758.570.09715
=26.8N-m
n
Total torque tranmitted

291.78
Torque tranmitted by one plate

26.8
n =10.88 say 11
Number of plates required n = 11
Belt:
To transmit power from one shaft to another, pulleys are mounted on the two
shafts. The pulleys are then connected by an endless belt or rope passing over the
pulleys. The connecting belt or rope is kept in tension so at motion of one pulley is
transferred to the other without slip.
The speed of the driven shaft can be varied by varying the diameters of the two
pulleys.
OPEN AND CROSS BELT DRIVES:
1. Open belt drive
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An open belt drive is used when the driven pulley is desired to be rotated in same
direction as the driving pulley as shown in Figure
Generally, the centre distance for an open-belt drive is 14 to 16 m.
2. Crossed or twist belt drive
When there is no slip, then v1= v2
d1 N1 d 2 N 2
60
60
N 2 d1
N1 d 2
Velocity ratio of compound belt drive:
A crossed-belt drive is
adopted when the driven
pulley is to be rotated in
opposite direction to that of
the driving pulley
A cross belt drive can
transmit more power than an
open-belt drive as the angle of
wrap is more.
However, the belt has to
bend in two different planes
and it wears out more.
Velocity Ratio of Belt Drive
d1= Diameter of the driver,
d2= Diameter of the follower,
N1=Speed of the driver in r.p.m and
N= Speed of the follower in r.p.m
Length of the belt that passes over the driver, in one minute = d1N1
Velocity ratio of pulleys 1 and 2
N 1 d1
------- (i)
N2 d2
Velocity ratio of pulleys 3 and 4,
N
d
Velocity ratio 2 1
N1 d 2
N4 d3
------------- (ii)
N3 d4
When the thickness of the belt (t) is considered, then velocity ratio
Velocity ratio
Multiplying equations (i) and (ii),
N 2 d1 t
N1 d 2 t
Peripheral velocity of the belt on the driving pulley, v1
d1 N1
60
Peripheral velocity of the belt on the driven or follower pulley, v 2
N 2 N 4 d1 d 3
N1 N 3 d 2 d 4
N 4 d1 d 3
N1 d 2 d 4
d 2 N 2
60
(N2=N3, being keyed to the same shaft)
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if there are six pulleys, then
N 6 d1 d 3 d 5
N1 d 2 d 4 d 6
Speed of last driven
Product of diameters of drivers
Speed of first driver

Product of diameters of drivens
Slip of Belt:
Velocity of the belt passing over the driver per second
d1 N 1
s
1 1
60
100
Velocity of the belt passing over the follower per second
d N
s
v 2 2 1 2
60
100
N2
d
s
1 1
N1 d 2
100
L r1 r2 2 x
L
r1 r2 2
x
d1 d 2 2 x d1 d 2
2
4x
Length of a Cross Belt Drive:
(s=s1+s2)
If thickness of the belt (t) is considered, then
N2
d t
s
1
1
N1 d 2 t
100
Creep of Belt:
1, 2 - Stress in the belt on the tight and slack side respectively, and
E = Youngs modulus for the material of the belt
E 2
N2
d
1
N1 d 2 E 1
Length of Open Belt Drive:
L r1 r2 2 x
r1 r2 2
x
d1 d 2 2
L d1 d 2 2 x
2
4x
Power Transmitted by a Belt:
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T1 and T2 = Tensions in the tight and slack side of the belt respectively in N
r1 and r2 = Radii of the driver and follower respectively, and
v = Velocity of the belt in m/s
The effective turning (driving) force at the circumference of the follower is the
difference between the two tensions (i.e. T1 - T2)
Work done per second (or) power transmitted = (T1 - T2) v
Ratio of Driving Tensions for Flat Belt Drive:
T1
e
T2
Angle of contact or lap:
Open belt drive
180 2
rad
180
r1 r2
Tr1 TC
Tr 2 TC
2.3 log
Maximum Tension in the Belt

Centrifugal tension is considered, then T = T1 + TC
Power transmitted by a belt P = (T1-T2) v
P = (T-TC) v.C
= (T-mv2) v.C
= (T.v-mv3) C
(Substituting Tc = mv2)
2
T -3mv = 0
T -3TC=0
T=3TC
Notes:
1. T1 =T-TC and for maximum power
T
2T
T1 T
3
3
sin -1
2. Velocity of the belt for the maximum power
Cross belt drive:
Initial Tension in the Belt:
180 2
rad
180
r1 r2
sin -1
Centrifugal Tension:
Tc mv 2
Tr1 Maximum or Total tension in the belt
Notes:
1. When the centrifugal tension is taken into account, then total tension in the tight
side,
Tr1 = T1+TC
and total tension in the slack side, Tr2 = T2+TC
2. Power transmitted P = (Tr1-Tr2) v = [(T1+TC) (T2-TC)] v = (T1-T2) v
Thus we see that centrifugal tension has no effect on the power transmitted.
3. The ratio of driving tension may also be written as
T0
T
3m
T T2 2TC
T1 T2
1
2
2
4. Find the power transmitted by a belt running over a pulley 700mm diameter
at 300 rpm, =0.3 and angle of lap 1600 and maximum tension in the belt is
2.453kN.
Given:
Pulley diameter d1= 700 mm=0.7m
Speed N1=300 rpm
Coefficient of friction = 0.28
Angle of lap = 1600 =2.793 rad
Maximum tension in belt T1= 2.453 kN = 2.453103 N
To find:
Power transmitted by the belt
Solution:
Power transmitted P = (T1 - T2) v
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T1
e
T2
T1
e 0.282.793
T2
T1
2.186
T2
T1
2.453 10 3
T2
2.186
2.186
T2 1222.33 N
N1d1 N 2 d 2
60
60
N1d1
300 0.7
=10.996 m/s
v v1
60
60
v v1 v2

= (2453 1222.33) 10.996
=13531.92 W
= 13.53 kW
5.Two pulleys, one 450 mm diameter and other 200mm diameter are in parallel
shafts 1.95m apart and are connected by a cross belt. Find the length of the belt
required and angle of contact between the belt and each pulley. What power can
be transmitted by the belt when the larger pulley rotates at 200 rpm if the
maximum permissible tension in the belt is 1kN and the co efficient of friction
between the belt and pulley is 0.25?
Given:
Diameter of pulley 1, d1= 450 mm=0.45m
r1 = d1/2= 0.225m
Diameter of pulley 2, d2=200 mm=0.2m
r2 = d2/2= 0.1m
Centre distance x = 1.95 m
Cross belt drive
Speed of the larger pulley N1=200rpm
Maximum tension in the belt Tmax = 1 kN
Coefficient of friction between belt and pulley =0.25

To find:
(i)
Length of the belt
(ii)
Angle of contact between belt and each pulley
(iii)
Solution:
(i)Length of the belt
L r1 r2 2 x
r1 r2 2
x
0.225 0.1 2 1.95
0.225 0.1 2
1.95
= 1.02+3.9+0.0542
L = 4.974 m
(ii)Angle of contact between belt and each pulley:
180 2
rad
180
r1 r2
0.225 0.1
= 9.35
sin -1
1.95
x
sin -1
rad 180 2 9.35

180
180
(iii) Power transmitted by the belt
180 2
= 3.46 rad
T1
e
T2
T1
e 0.253.46
T2
T1
2.379
T2
T2
T1
2.379
(1)
Tmax = T1= 1 kN =1000 N
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Substitute T1 value in equ.(1)
1000
T2
2.379
T2= 420.34 N
v v1 v 2
v
d1 N1 d 2 N 2
60
60
d1 N1
0.45 200
4.712 m/s
60
60
Power transmitted P = (T1 - T2) v = (1000 - 420.34) 4.712 = 2731.34 W

6. A 100 mm wide and 10 mm thick belt transmits 5 kW of power, between two
parallel shafts. The distance between the shaft centres is 1.5 m and the diameter
of the smaller pulley is 440 mm. The driving and driven shafts rotate, at 60 rpm
and 150 rpm respectively. The coefficient of friction is 0.22. Find the stress in
the belt if the two pulleys are connected by
(1) An open belt and
(2) A cross belt.
Given:
Width of the belt w = 100mm
Thickness of the belt t =10 mm
Transmitted power P = 5 kW
Centre distance x = 1.5 m
Diameter of the smaller pulley d2 = 440 mm
Speed of the driving shaft N1 = 60rpm
Speed of the driven shaft N2 = 150 rpm
To find:
Stress in the belt when two pulleys are connected by
(i)
An open belt
(ii)
A cross belt
Solution:
Open belt drive:
Stress
Tmax
b.t
Tmax = T1
v v1 v2
N1 d1 t N 2 d 2 t
150 0.44 0.01
60
60
60
v 3.535 m/s
T1
e
T2
180 2
rad
180
r1 r2
N 2 d1 r1
N1 d 2 r2
sin -1
N2
150
0.44
=1.1m
60
N1
d1 d 2
r1 = d1/2 =1.1/2 = 0.55 m
r1 r2
0.55 0.22
= 12.710
sin -1
1
.
5
x
sin -1
180 2
rad 180 2 12.71

180
180
= 2.7 rad
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T1
e
T2
sin -1
T1
e 0.222.7
T2
180 2
T1
1.811
T2
T1
e
T2
T2
r1 r2
0.55 0.22
= 30.870
sin -1
1
.
5
x
T1
1.81
T
5 10 T1 1 3.535
1.81
1.81T1 T1
1414.43
1.81
2560.12 1.81T1 T1
2560.12
3160.64 N
0.81
T1
Stress
Tmax
T
3160.64
3.1606 10 6 N/m 2
1
0.1
0.01
b.t
b.t
= 3.1606 N/mm2
T1
2.53
T2
T2
T1
2.53
5 10 3 T1 1 3.535
2.53
2.53T1 T1
2.53
3578.94 2.53T1 T1
1414.43
3578.94
1.53
T1
Tmax
T
1
b.t
b.t

v 3.535 m/s
T1
e
T2
180 2
= 4.22 rad
T1
e 0.224.22
T2
Cross belt drive:
Stress
rad 180 2 30.87

180
180
rad
180
T1 2339.17 N
Stress
Tmax
T
1
b.t
b.t
2339.17
2.339 10 6 N/m 2
0.1 0.01
= 2.339 N/mm2
7. Find the power transmitted by a belt running over a pulley 700mm diameter
at 300 rpm, =0.3 and angle of lap 1600 and maximum tension in the belt is
2.453kN.
Given:
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Pulley diameter d1= 700 mm=0.7m
Speed N1=300 rpm
Angle of lap = 1600 =2.793 rad
Maximum tension in belt T1= 2.453 kN = 2.453103 N
To find:
Solution:
T1
e
T2
Speed of smaller shaft N2=240 rpm

Speed of bigger shaft N1= 160 rpm
Thickness of belt t =8mm
Smaller pulley diameter d2= 600 mm
Centre distance = 5 m
Maximum stress in the belt = 3 N/mm2
To find:
Width of the belt by
(i)
An open belt drive
(ii)
A cross-belt drive
Solution:
Open belt drive:
T1
e 0.282.793
T2
T1
2.186
T2
T2
T2
T1
2.186
2.453 10 3
1222.33 N
2.186
N1d1 N 2 d 2
60
60
N1d1
300 0.7
=10.996 m/s
v v1
60
60
v v1 v2
Power transmitted P = (T1 - T2) v = (2453 1222.33) 10.996=13531.92 W

P =13.53 kW
8. A belt drive transmits 8 kW of power from a shaft rotating at 240 rpm to
another shaft rotating at 160 rpm. The belt is 8 mm thick. The diameter of the
smaller pulley is 600 mm and the two shafts are 5 m apart. The coefficient of
friction is 0.25. If the maximum stress in the belt is limited to 3N/mm 2, find the
width of the belt for : (1) An open belt drive (2) A cross-belt drive.
Given:
Power transmitted by the belt = 8kW
Tmax
b.t
T
width b max
.t
Stress
Tmax = T1
N1 d1 t N 2 d 2 t
60
60
N 2 d 2 t 240 0.6 0.08
v v2
8.545 m/s
60
60
v v1 v2
T1
e
T2
Page 13
KOM

180 2
rad
180
2023.17
1.161
T1
r1 r2
N 2 d1 r1
N1 d 2 r2
sin -1
T1 1742.61 N
Width b
N2
240
0. 6
160
N1
d1 d 2
b = 7.26 mm
Cross belt drive:
d1=0.9m
r1 = d1/2 =0.9/2 = 0.45 m
width b
r1 r2
0.45 0.3
= 1.7190
sin -1
5
x
sin -1
180 2
rad 180 2 1.719

180
180
Tmax
T
1742.61
1
7.26 10 -3 m
6
.t
.t
3 10 0.08
Tmax
.t

v 8.545 m/s
= 3.08 rad
T1
e
T2
T1
e
T2
180 2
T1
e 0.253.08
T2
sin -1
T1
2.161
T2
180 2
T2
T1
2.161
T1
8 10 T1
8.545
2.161
2.161T1 T1
936.22
2.161
2023.17 2.161T1 T1
rad
180
r1 r2
0.45 0.3
= 8.6270
sin -1
5
x
rad 180 2 8.627

180
180
= 3.443 rad
T1
e
T2
T1
e 0.253.443
T2
T1
2.365
T2
T2
T1
2.365
Page 14
KOM

T1
8 10 T1
8.545
2.364
2.365T1 T1
936.22
2.365
2214.16 2.365T1 T1
2214.16
1622.1 N
1.365
Tmax
T
1622.1
1
6.76 10 -3 m
6
.t
.t
3 10 0.08
b = 6.76 mm
9. Two pulleys, one 450mm diameter and other 200mm diameter are on parallel
shafts 2.1 m apart and are connected by a belt, as a cross belt drive. The larger
pulley rotates at 225 rpm. The maximum permissible tension in the belt is 1kN
and the coefficient of friction between the belt and pulley is 0.25.Find the power
that can be transmitted.
Given:
Diameter of the pulley one d1= 700 mm=0.7m
r1=0.35m
Diameter of the second pulley d2= 200 mm=0.2m
r2=0.1m
Centre distance x = 2.1m
Speed of larger pulley N1 =225 rpm
Maximum tension in belt T1= 1 kN = 1103N
To find:
Solution:
T1
e
T2
180 2
rad
180
180 2
rad 180 2 6.837

180
180
= 2.903 rad
T1
e
T2
T1
Width b
r1 r2
0.35 0.1
= 6.8370
sin -1
2
.
1
x
sin -1
(Assume, open belt drive)
1 10 3
e 0.252.903
T2
T2 = 483.96 N
N1d1 N 2 d 2
60
60
N1d1
225 0.7
= 8.247 m/s
v v1
60
60
v v1 v2
Power transmitted P = (T1 - T2) v = (1000 483.96) 8.247 = 4255.62 W

10. A leather belt is required to transmit 7.5 kW from a pulley 1.2m in diameter,
running at 250 rpm. The angle embraced is 165 0 and the coefficient of friction
between the belt and the pulley is 0.3. The safe working stress for the leather
belt is 1.5MPa; the density of leather is 1000kg/m 3 and thickness of belt is
10mm. Determine the width of the belt taking centrifugal tension into account.
Given:
Power P = 7.5 kW
Diameter of pulley d1 = 1.2 m
Speed of the pulley N1= 250 rpm
Angle of contact = 1650 = 2.88 rad
Coefficient of friction =0.3
Safe working stress = 1.5MPa = 1.5103 N/m2
Density of material = 1000 kg/m3
Thickness of belt t = 10 mm
To find:
Width of the belt
Solution:
Stress
Tmax
b.t
Page 15
KOM

b
Tmax
t
Tmax = T1 +TC
N1d1 N 2 d 2
60
60
N1d1
v v1
60
v v1 v2
250 1.2
60
v =15.71 m/s
T1
e
T2
T1
e 0.32.88
T2
m V 1000 b 0.01 1
m=10 b
TC = mv2 = 10b 15.712 = 2468.04 b
Tmax = T1 +TC = 825.11+2468.04b
Tmax
.t
825.11 2468.04b
b
1.5 10 6 0.01
width b
15000 b = 825.11+2468.04b
12531.96 b = 825.11
825.11
b
12531.96
b 0.06584 m = 65.84 mm
T1
2.373
T2
T1
7.5 10 3 T1
15.71
2.373
2.373T1 T1
2.373
1132 .88 2.373T1 T1

477.403
1132 .88
1.373
T1
T1 825.11 N
TC = mv2
m V
V bt L
Assume, L = 1m
V b 0.01 1
Part-A
1. List down the laws of friction. (May/June 2013, R2008/2010)
2. State the laws of dry friction. (May/June 2013, R2004/2007)
3. Differentiate between self locking and overhauling of screw. (May/June 2012,
R2008)
4. State the condition of self locking of screw jack (Nov/Dec 2014, R2004/2007)
5. Why self locking screws have lesser efficiency? (Nov/Dec 2012, R2008)
6. What is the maximum efficiency a screw jack? (May/June 2014, R2004/2007)
7. What is friction angle? (Nov/Dec 2014, R2008/2010)
8. Define anti -friction bearing. (Nov/Dec 2013, R2008/2010)
9. Differentiate multiplate clutch and cone clutch. (Nov/Dec 2013, R2008/2010)
10. Mention the significance of multi-plate clutch. (Nov/Dec 2013, R2004/2007)
11. Define velocity ratio (May/June 2014, R2008/2010)
12. Distinguish between open and cross belt drive in terms of its application.
(May/June 2013, R2008/2010)
Page 16

13. In an open belt drive the diameter of the smaller pulley is 250 mm. The diameter
of the bigger pulley is 400 mm, and the centre distance is 2.0 m. find the angle of lap
for the smaller pulley. (May/June 2013, R2004/2007)
14. State the functional difference between a clutch and a brake. (May/June 2012,
R2008)
15. The brake drum of a single block brake of diameter 320 mm is rotating at 420
rpm. If the angle of contact is 90 0, co-efficient of friction between the drum and
brake block is 0.25, determine the equivalent co-efficient of friction (Nov/Dec 2013,
R2004/2007)
16. What is meant by a self-locking and self-energised brake? (Nov/Dec 2012,
R2008)
Part-B
Friction in screw threads:
1. List the various types of friction. (4) (Nov/Dec 2013, R2008/2010)
2. Derive the force analysis of a body resting on an inclined plane with force inclined
to the plane. (12) (Nov/Dec 2013, R2008/2010)
3. Derive an expression for the effort required to raise a load with screw jack taking
friction into consideration.(8) (May/June 2014, R2008/2010)
4. A square threaded bolt with a core diameter of 25 mm and pitch of 10mm is
tightened by screwing a nut. The mean diameter of the bearing surface of the nut is
60 mm. The coefficient of friction for the nut and bolt is 0:12 and for the nut and
bearing surface it is 0.15. Determine the' force required at the end of a 400 mm long
spanner, if the load on the bolt is 12kN. (6) (Nov/Dec 2014 R2004/2007, Nov/Dec
2013, R2004/2007)
5. A 150mm diameter value, against a steam pressure of 2MN/m 2 is acting, is closed
by means of a square threaded screw 50mm in external diameter with 6 mm pitch. If
the coefficient of friction is 0.12, find torque required to turn the handle. (8)
(May/June 2014, R2008/2010)
6. The mean diameter of the screw jack having pitch of 10mm is 50mm. A load of
20kN is lifted through a distance of 170 mm. Find the work done in lifting the load
and efficiency of the screw jack when (i) the load rotates with the screw, and (ii) the
load rests on the loose head which does not rotate with screw. The external and
internal diameter of the bearing surface of the loose head is 60mm and 10mm
KOM
respectively. The coefficient of friction for the screw as well as the bearing surface
may be taken as 0.08. (May/June 2013, R2004/2007)
7. A screw-jack has a square thread of mean diameter 60mm and pitch 8mm.The
coefficient of friction at the screw thread is 0.09.A load of 3kN is to be lifted through
120mm. Determine the torque required and the work done in lifting the load through
120mm.Find also the efficiency of the jack.(8) (Nov/Dec 2012, R2008)
8. The following data related to a screw jack; Pitch of a thread screw = 8mm,
diameter of the screw thread = 40mm, Coefficient of friction between screw and nut
= 0.1, Load = 20kN.Assuming that the load rotates with screw, determine:
(i)
The ratio of torques required to raise and lower the load.
(ii)
The efficiency of the machine.(6)(May/June 2012, R2008)
Bearings:
9. In a thrust bearing, the external and internal diameters of the contacting surfaces
are 320mm and 200mm respectively. The total axial load is 80kN and the intensity of
pressure is 350kN/m2. The shaft rotates at 400rpm. Taking the coefficient of friction
as 0.06, calculate the power lost in overcoming the friction and the number of collars
required. (8)
(Nov/Dec 2012, R2008)
10. A vertical shaft of 100mm diameter rotating at 150 rpm rests on a flat end foot
step bearing. The coefficient of friction is equal to 0.05 and shaft carries a vertical
load of 15 kN. Find the power lost in friction assuming the following conditions:
(1) Uniform pressure
(2) Uniform wear.
(6) (May/June 2013, R2008/2010)
11. A vertical shaft 140 mm diameter rotating at 120 rpm rests on a flat end foot step
bearing. The shaft carries a vertical load of 30 kN. The coefficient of friction is 0.06.
Estimate the power lost is friction, assuming uniform pressure and uniform wear. (8)
(Nov/Dec 2013, R2008/2010)
Clutches:
12. With a neat sketch, explain the working of a multi-plate clutch. (8)
(Nov/Dec 2014, R2004/2007)
16. A single plate clutch both sides effective, has outer and inner diameters 300mm
and 200mm respectively. The maximum intensity of pressure at any point in the
contact surface is not to exceed 0.1N/mm 2. If the coefficient of friction is 0.3,
determine the power transmitted by a clutch at a speed 2500rpm for two types of
Page 17

assumptions, that is, for uniform pressure and uniform wear (10) (May/June 2012,
R2008)
13. A friction clutch of multi-plate type is meant for transmitting a power of 55 kW at
1800 rpm. Coefficient of friction for the friction surfaces is 0.1. Axial intensity of
pressure is not to exceed160 kN/m2. The internal radius is 80 mm and is 0.7 times the
external radius. Determine the number of plates needed to transmit the required
torque. (10) (May/June 2013R2008/2010, Nov/Dec 2013, R2008/2010)
15. A friction clutch is used to rotate a machine from a shaft rotating at a uniform
speed of 250 rpm. The disc-type clutch has both of its sides effective, the coefficient
of friction being 0.3. The outer and the inner diameters of the friction plate are 200
mm and 120 mm respectively. Assuming uniform wear of the clutch, the intensity of
pressure is not more than 100 kN/m 2. If the moment of inertia of the rotating parts of
the machine is 6.5 kg-m2. Determine the time to attain the full speed by the machine
and the energy lost in slipping of the clutch. What will be the intensity of pressure if
the condition of uniform pressure of the clutch is considered? Also, determine the
ratio of power transmitted with uniform wear to that of uniform pressure. (Nov/Dec
2013, R2004/2007)
Belt
17. Derive an expression for the centrifugal tension in a belt passing round a pulley
rim (6) (Nov/Dec 2012, R2008)
18.Two pulleys, one 450 mm diameter and other 200mm diameter are in parallel
shafts 1.95m apart and are connected by a cross belt. Find the length of the belt
required and angle of contact between the belt and each pulley. What power can be
transmitted by the belt when the larger pulley rotates at 200 rpm if the maximum
permissible tension in the belt is 1kN and the co efficient of friction between the belt
and pulley is 0.25? (16) (May/June 2014, R2008/2010)
19. A 100 mm wide and 10 mm thick belt transmits 5 kW of power, between two
parallel shafts. The distance between the shaft centres is 1.5 m and the diameter of
the smaller pulley is 440 mm. The driving and driven shafts rotate, at' 60 rpm and
150 mm respectively. The coefficient of function is 0.22. Find the stress in the belt if
the two pulleys are connected by
(1) An open belt and (5)
(2) A cross belt. (5) (Nov/Dec 2014, R2004/2007)
KOM
20. Two shafts whose centres are 1 m apart are connected by a V belt drive.
The driving pulley is supplied with 100 KW and has an effective diameter of 300
mm. It runs at 375 rpm. The angle- of groove on the pulley is 40 .The permissible
tension in 400 mm2 cross sectional area of the belt is 2.1 MPa. The density of the belt
is 1100 kg/mm3 and Coefficient of friction is0.28. Estimate number of belts required.
(May/June 2013, R2004/2007)
21. Find the power transmitted by a belt running over a pulley 700mm diameter at
300 rpm, =0.3 and angle of lap 1600 and maximum tension in the belt is 2.453kN.
(6) (May/June 2013, R2008/2010)
22. A belt drive transmits 8 kW of power from a shaft rotating at 240 rpm to another
shaft rotating at 160 rpm. The belt is 8 mm thick. The diameter of the smaller pulley
is 600 mm and the two shafts are 5 m apart. The coefficient of friction is 0.25. If the
maximum stress in the belt is limited to 3 N/mm2, find the width of the belt for
(1) An open belt drive (5)
(2) A cross-belt drive. (5) (Nov/Dec 2013, R2004/2007)
23. Two pulleys, one 450mm diameter and other 200mm diameter are on parallel
shafts 2.1 m apart and are connected by a belt, as a cross belt drive. The larger pulley
rotates at 225 rpm. The maximum permissible tension in the belt is 1kN and the
coefficient of friction between the belt and pulley is 0.25.Find the power that can be
transmitted. (8) (May/June 2012, R2008)
24. A leather belt is required to transmit 7.5 kW from a pulley 1.2m in diameter,
running at 250 rpm. The angle embraced is 1650 and the coefficient of friction
between the belt and the pulley is 0.3. The safe working stress for the leather belt is
1.5MPa; the density of leather is 1000kg/m 3 and thickness of belt is 10mm.
Determine the width of the belt taking centrifugal tension into account. (10)
(Nov/Dec 2012, R2008)
Rope:
25. The following data relate to a rope drive:
Power transmitted = 20 kW; Diameter of pulley = 480mm; Speed = 80rpm
Angle of lap on smaller pulley = 160; Number of ropes = 8
Mass of rope/m length = 48 G2 kg
Limiting working tension = 132 G2 kN
Angle of groove = 440
If C is the girth of rope in m. Determine the initial tension and diameter, of each
rope. (Nov/Dec 2014, R2004/2007)
Page 18
KOM
Brake:
26. A simple brake as shown in Figure is used on a shaft carrying a flywheel of mass
450 kg. The radius of gyration of the flywheel is 500 mm. and runs at 320 rpm. The
coefficient of friction is 0.2 and the diameter of brake drum is 250 mm, determine the
following:
(1) Torque applied due to a hand load of 150N (4)
(2) The number of turns of the wheel before it is brought to rest. (4)
(3) The time required to bring it to rest from the moment of application of the
brake. (2) (May/June 2013, R2008/2010)
27. In a simple band brake, one end of the band is attached to the fulcrum of a lever.
The other end is attached at a distance of b from the fulcrum. The effort is applied at
the end of the lever. Derive an expression for braking torque, in terms of effort. (8)
(May/June 2012, R2008)
Page 19

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KOM

Unit V: Friction in Machine Element

Department of Mechanical, AAMEC

Skin friction is also termed as boundary friction.

Unit V: Friction in Machine Element

In a cone clutch as shown in

Department of Mechanical, AAMEC

Centrifugal clutches are being increasingly used in automobiles and machines.

Unit V: Friction in Machine Element

n1 - No. of discs on the driving shaft

For Single plate clutch

Department of Mechanical, AAMEC

Energy lost due to friction = T(1- 2)

Unit V: Friction in Machine Element

Department of Mechanical, AAMEC

Unit V: Friction in Machine Element

Ratio of Power transmitted with uniform wear to that of uniform pressure

Torque transmitted, T = n..W.R = 2 0.3 1507.96 0.08 = 72.38 N-m

Department of Mechanical, AAMEC

1 = t =26.182.35 = 61.5 rad

p = 75000 N/m2 = 75 kN/m2

Unit V: Friction in Machine Element

Total torque tranmitted

Total torque transmitted T = P/

Department of Mechanical, AAMEC

Torque transmitted by one plate

Total torque tranmitted

Torque tranmitted by one plate

Unit V: Friction in Machine Element

2. Crossed or twist belt drive

When there is no slip, then v1= v2

Velocity ratio of pulleys 1 and 2

Multiplying equations (i) and (ii),

Peripheral velocity of the belt on the driving pulley, v1

Peripheral velocity of the belt on the driven or follower pulley, v 2

Department of Mechanical, AAMEC

(N2=N3, being keyed to the same shaft)

Unit V: Friction in Machine Element

Speed of first driver

Velocity of the belt passing over the follower per second

Length of a Cross Belt Drive:

Department of Mechanical, AAMEC

Unit V: Friction in Machine Element

Maximum Tension in the Belt

2. Velocity of the belt for the maximum power

Cross belt drive:

Initial Tension in the Belt:

Department of Mechanical, AAMEC

Unit V: Friction in Machine Element

Power transmitted P = (T1 - T2) v

Department of Mechanical, AAMEC

Coefficient of friction between belt and pulley =0.25

0.225 0.1 2 1.95

rad 180 2 9.35

Tmax = T1= 1 kN =1000 N

Unit V: Friction in Machine Element

Power transmitted P = (T1 - T2) v = (1000 - 420.34) 4.712 = 2731.34 W

Open belt drive:

r1 = d1/2 =1.1/2 = 0.55 m

Department of Mechanical, AAMEC

rad 180 2 12.71

Unit V: Friction in Machine Element