Department of M3

MMME2034 (MM2DMP) Design, Manufacture and

project
Project Brief: Centrifugal Clutch
Project Type: Design, Make and Test
PDR Deadline: Wednesday 23rd October 2019 (In-class and
Moodle Submission)
SDR Deadline: 25th - 29th November 2019 (Online Submission)
CDR Deadline: 6th December 2019 (Hardcopy and Moodle
Submission)

This is a group design, make and test exercise to produce a prototype to

demonstrate the proof of concept for a centrifugal clutch.

1. Learning Outcomes
After successful completion of this project students will have the ability to:
• Visualise a solid object while “looking” at an engineering drawing.
• Research and evaluate different architectures for combining given machine
elements.
• Work effectively as a team.
• Design machined and hand fitted parts.
• Produce physical and computer models of mechanisms.
• Define parts for prototype manufacture through the medium of detail
drawings.
• Manufacture and test a complete high precision piece of equipment.
• Select appropriate materials and processes.
• Understand the reasons for prototyping.

2. Background
• You are Design Engineers working in a Company which designs and
manufactures clutches and drives for industrial and medical use. The
Company need to develop new lining materials.
• Prototypes are used for a variety of purposes:
• To acquire data (research).
• To demonstrate proof of concept (risk reduction).
• To demonstrate compliance (‘customer’ approval).
• Before embarking on full scale manufacture a prototype rig is required to
conduct the research.
3. Requirements
A rig which simulates the arrangement is shown in Fig 1.

1. To be capable of transmitting a torque of 0.3 Nm when the input speed

is above 2000 rpm.
2. To disconnect the drive when the input speed is below 1500 rpm.
3. To be capable of running with negligible maintenance for 5000 hours.
4. To mount to a given set of interfaces. Detail drawings are provided in
figures 3 and 4. Connection to the Oldham coupling is a simple spindle
8.00mm g6 dia. x 20mm long.
5. To be capable of being manufactured in EA Workshops
6. The parts to be designed and made are the ones in red in Figure 1.
7. Some pre machined parts are available, SolidWorks models are in the
Centrifugal Clutch folder on Moodle
8. The materials for the rig must be selected from the list in section 9. In
exceptional circumstances, and with agreement of the Tutor, if
the proposed concept is considered novel and can only be achieved with
alternative material then this may be selected from the stores catalogue.

Figure 1: Diagrammatic Layout

4. Deliverables
The design and make phases of the project are group work. It is expected that
each student will contribute equal effort. It is each individual group member’s
responsibility to work efficiently and effectively within the team.
Individual students should initial each sheet and drawing which they have
produced or checked.
Each group must make submissions in three parts:

1. PDR - Preliminary Design Review (in class submission to the group tutor)
2. SPR – Self & Peer Review (survey)
3. CDR - Critical Design Review (Hardcopy submission at BB73 and Moodle
submission)
The PDR, which will be marked, should comprise:

1. Group Coursework cover sheet.

2. An Executive Summary is required which answers the Board’s questions
with justification. (guide 200 words maximum*)
3. A clear definition of the likely concept evaluated and selected by the
group. It should also contain a scanned pencil drawing of the concept or
an outline SolidWorks GA, both to have key dimensions)
4. Preliminary calculations in a neat and auditable manner to justify the
answers to item 2. Calculation should include shoes dimensions,
centrifugal, spring actuation forces and moments, Torque and power at
key speeds
5. Preliminary choice of materials, with justification.
6. Each group member should have produced at least one signed concept
design which should be attached as an appendix.
7. Hardcopy should be submitted to the group tutor during Design Office
session on 23th October and softcopy has to be uploaded in Moodle by
the group leader only.
8. You are expected to submit the cutting list on 11:00 on Wednesday
13th November 2019 during the design office class for review. The
feedbacks will be given back to you to be corrected and incorporated in
your final report for final submission.*
* Two copies will be required one for the tutor and one for the Workshop.
Each group must submit a final report CDR which shall comprise:
9. Group Coursework cover sheet.
10. Table of contents and a short introduction (300 words max).
11. A final Executive report updated as a result of further design work (500
words maximum).
12. Final design calculations representative of the final design.
Calculation should include the updated version of PDR calculations and
stress analysis of the shaft. Final dimensions used in the CDR calculation
must match with dimension used in GA and detail drawings of parts.
13. Final choice of materials, with justification
 14. Two General Arrangement (GA) drawings: (a) The prototype on its own
with its BOM) (b) Prototype assembled onto the test rig, Figure 2
(SolidWorks model is on Moodle).
15. The assembly drawings should make full use of sections to show exactly
how everything fits together and to allow verification of the component
sizing. Include limits, fits and clearances for critical parts. Subassembly
drawings are likely to be useful.
16. Detail drawings of the individual parts which must be fully dimensioned
and show tolerances so that any competent machinist could produce with
only the drawing as reference.
17. Process sheets for the manufacture of each part.
18. A cutting list for raw material and components. Two copies will be
required one for the tutor and one for the Workshop.
19. A manufacturing plan showing who, what and when for each component
will be produced.

5. Process sheets and cutting list

Each part should have a Process sheet describing to a machinist/fitter how it is to
be made.
The process sheet will always be used in conjunction with the part’s detail drawing.
Do not duplicate information that is on the drawing (especially dimensions) as
modifications may make one version out of date and using the wrong version will
result in scrapped parts.
Use the knowledge of the tutors and technicians to refine the design and to write
a good process sheet for the part.
Enough material to allow for clamping or chucking on the machine should be
provided.

6. Organisation
This is a group exercise and there will be an assigned tutor (analogous with the
design leader in industry).
Formal project management is not required, but attendance at Design Office
will be registered and it is important that the following schedule is maintained.
Your design tutor may have their own opinions as to the “best” way to solve a
particular problem. They may also place greater emphasis on certain features of
the design which they believe are important. This advice may not be the same as
the advice being given by other design tutors. You are advised to follow the lead
of your own design tutor as they will be marking your work.
The design part of this project amounts to around 30 hours of work for each
member of the team.
Time Lines:
Date Bring to Design Office... Work in Design Office...
25 Sep 19 Project Brief
2 Oct 19 Understanding of Brief. Discuss the requirements and
Sketches of possible outline any calculations needed
architecture
9 Oct 19 Sketches of proposals and Explain your choice of concepts
preliminary calculations. and iterations.
16 Oct 18 Options for architecture and Discuss and develop the concepts
sketches for tutor comments
23 Oct 19 Hardcopy submission of Concept modelling and initial
PDR to your tutor in class assembly
(the softcopy must be
uploaded to the Moodle by
the group leader)
30 Oct 19 Tutors hand back marked GA drawing and preparing cutting
reports list
Check your mark and return back
the report to the convenor by the
end of session
6 Nov 19 Cutting list submission to Cutting list review by Tutor
Tutor Revising and updated GA
13 Nov 19 Detail drawings Tutor review
Final Cutting list
submission to the
convenor
20 Nov 19 Initial Process sheets Tutor review
27 Nov 19 Full set of drawings Tutor review and technician’s
SPR Submission (ONLINE support on the preparation of
SURVEY) – 25th - 29th Cutting List, Process Sheets, and
Nov manufacturing plan
4 Dec 19 Set of complete detail Tutor review
drawings and GAs
manufacturing plan
6 Dec 19 Hand in deadline for CDR. This data goes to the tutor and
One copy of full set of the workshop in preparation for
documents including front next semester
cover sheets, report, GA
and detail drawings,
cutting list and process
sheets. Another copy of
only front cover sheets,
GA and detail drawings,
cutting list and process
sheets
Jan 2020 Timetabled workshop
and through sessions in EA workshop for
term manufacture.
 Spring Testing
2020(tbc)

The Make/Test activity

Timetabled slots in the EA workshop will be allocated. No other time will be allowed
in the workshop. As resources are finite it will be advantageous to have few
and simple parts.
To maximise the time it is important that everyone is involved in the manufacture,
also it is vital that there are clear, unambiguous and checked detail drawings and
process sheets to avoid rework. Drawings should be checked by a different
member of the group to the producer.
The technicians are in the workshop to help with the details of machining. Arrive
at the sessions on time having planned what is to be done. Make sure there is an
up-to-date version of the drawings and process sheets. Making a really accurate
part to an out-dated drawing is a total waste of time and materials.

7. Marking and Feedback

The marking and feedback sheets are attached. The design activity is worth 15%
of the marks of the module which comprises of:
• PDR 20%
• SPR 20%
• CDR 60%

PDR (20%)
The team submission will be assessed according to the marking schedule.
Report 3 marks
• Structured correctly and presented appropriately.
• Clear introduction and concise summary of initial conclusions
Concept Definition 7 marks
• Will it work for the specified function and performance?
• Is final concept is selected by Decision Matrix?
• Is due consideration given to the selection of appropriate components?
• Is due consideration given for manufacturing and assembly?
Calculations 7 marks
• Do the calculations relate to the question?
• Are the calculations clear and relate to the concept?
• Are the assumptions valid?
Choice of materials 3 marks
• Are the materials readily available
• Are the materials suitable for the performance and working conditions?
SPR (20%)

The Self & Peer Review (SPR) is aimed to quantify the contribution of each team
member towards the whole project delivery. You are expected to complete a
simple survey form to gain marks. Failure to complete this form will result
your individual marks to become 0% in total. The form link will be published
in Moodle; date will be announced later but tentatively would be near the end of
this project. Pay attention to your email!

CDR (60%)
The team submission will again be assessed according to the marking schedule.
Report – 8 marks
• Structured correctly and presented appropriately
• Clear introduction and concise summary of work
Engineering – 18 marks
• Will it work?
• Are limits and fits appropriate
• Is there clearance for moving parts
• Can it be manufactured
• Can it be assembled?
• Does it fit the test rig
Material selection - 5 marks
• Are suitable materials selected for the performance
• Is any heat treatment or condition required?
• Are they available
Calculation – 9 marks
• Shoes dimensions
• Centrifugal, spring actuaction forces and moments
• Torque and power at key speeds
• Stress analysis of the shaft
• Are the calculations consistent with the Design?
Assembly Drawings – 9 marks
• Are two drawings supplied?
• Parts list – all parts identified with BOM balloons, all necessary bought-
in part details or standards quoted, materials and quantities identified
• Layout - sufficient views – how is it assembled. A setting up procedure
to be included as text?
• Does it meet the design intent
• Are limits, fits and tolerances correctly identified?
Detail drawings – 8 marks
• Are the drawings to BS8888?
 • Are the drawings complete – are enough details given to define parts?
• Datum features established?
Manufacturing plan, cutting list and process sheets – 8 marks
• Do the process sheets define a sensible set of steps to manufacture
the given parts?
• Cutting list – is the cutting list clearly specified?

After the submission of CDR, the next step would be fabrication and testing of
your design and this will happen during mid-Spring semester. This is worth
another 12% of the marks of the module. Your prototype will be assessed by the
quality of workmanship and how well the device meets the requirements.
Attendance in the workshop and on testing day will also contribute to the final
mark.

8. Additional Notes and Guidance

To ensure smooth running it is very important that everything runs true i.e. that
all the parts are co-axial – i.e. have a common axis.
It is not satisfactory to rely on threaded fasteners locate parts accurately; threads
are never true and clearance holes are always significantly oversize. From the
interface drawing it can be seen that the driving flange has a tolerance spigot.
It is not good practice to use threaded fasteners to transmit torque unless it is
clear that the interface pressure generated by the threaded fasteners and
subsequent friction are capable of transmitting the torque without slip. As the
torque in this clutch is very low and it is only designed for one direction of rotation
then conventional fasteners for shaft flanges can be used. As part of the
calculations show this is the case, (hint look at plate clutch notes).
To obtain long life and low maintenance at the speeds involved, rolling element
bearings that are required will be supplied.

9. Supplied, Standard Parts and Materials

Materials that will be supplied:
• Mild steel tube 2mm wall thickness and with 101.6mm outside diameter.
Suitable for the drum.
• Mild steel plate of 3mm thick mild steel which can be cut into different sizes
of diameter. Suitable for the back plate, back of drum etc.
• Permali material is not available in Malaysia and we will replace it with high
grade wood. Dimension and property of the material can be assumed similar
to Permali with thickness of 19mm, density of 1400 kg/m3 , coefficient of
friction with steel = 0.25, pmax =100,000 N/m2
• Aluminum round bar of diameter 32 mm. Suitable for shaft.
• Aluminum round bar of diameter 60.0mm. Suitable for bearing housing.
• Deep groove ball bearings number 6201ZZ (32mm OD, 12mm ID, 10mm
thick)
• Tension spring and fitting
• Various set screws, nuts and washers with the minimum size to be M5.
• Any other request other than above will be scrutinized for approval and
should be selected from the list of materials in store.
• Pro-formas for Cutting Lists and Process Sheets are on Moodle. Only data
submitted in these formats will be acceptable
Figure 2: Rig Layout
Figure 3: Drive Adaptor