A cone clutch is another type of clutch used in automobiles. It serves the same purpose as a disk or plate clutch. However, instead of mating two spinning disks, the cone clutch uses two conical surfaces to transmit torque by friction.
When changing gear ratios, it is utilized to engage and release the engine shaft from the transmission box shaft. The torque is transmitted by friction between two conical surfaces in a cone clutch.
One surface is referred to as the male member, while the other is referred to as the female member. Well, in this reading, we’ll explore what a cone clutch is, its applications, parts and construction, diagram, and how it works. We’ll also explore its advantages and disadvantages.
Let’s begin!
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What is a Cone Clutch?
Clutches are mechanical devices that engage and disengage power transmission from the driving shaft to the driven shaft, primarily from the driving shaft to the driven shaft.
The clutch is located between the flywheel and the pressure plate. The driven shaft is usually attached to the engine, whereas the driving shaft provides output power.
It is a friction clutch that has cone-shaped frictional areas. These types of clutches are commonly used in synchromesh and epicyclic gearboxes.
Cone clutches were the first to be used in automobiles, and they remained popular due to their simplicity until the 1920s, when they were replaced by single-plate clutches due to the former’s poor operating qualities.
When opposed to a positive displacement clutch, which was utilized before cone clutches were designed, a cone clutch is easier to engage and disengage.
Because the cone clutch has a larger contact area than a plate clutch of the same size, it may transfer more torque. For the clutch to function properly, the driving and driven shafts must be exactly coaxial.
When high-torque transmission at low rotational speed is necessary, this clutch can be employed. As a result, heavier trucks commonly use this sort of clutch.
Applications of Cone Clutch
The following are the applications of a cone clutch.
- It is used as a synchronizer in a variety of manual transmissions.
- Because of their ability to transmit tremendous torque, they are used in a variety of heavy machinery.
- Clutches like these are typically employed in low-speed peripheral applications.
- It’s a popular choice for powerboats.
- In racing and rallying automobiles, this clutch is employed.
- It’s found in some cars and other types of combustion engine transmissions.
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Construction
A cone clutch is made up of two parts: a male and a female cone. The female portion is attached to the flywheel, which is bolted to the engine crankshaft and serves as a driving component.
The male component is divided into two halves, one of which is the central hub and the other of which is the outer cone. For strength, the cone section is composed of aluminum, while the hub is constructed of steel.
The male part’s hub is splined and fitted over the transmission’s input shaft, allowing it to travel axially over it. Friction materials are used to line the contact surfaces of the male and female parts.
A spring forces the male part against the female portion, and a throw-out bearing connected to the male part allows the parts to be disengaged.
Parts of the Cone Clutch
The following are the major parts of a cone clutch:
1. Female cone (outer cone): When the engine turns, the female part connected to the engine rotates, and the male part rotates owing to friction between the cone plates.
2. Male cone (inner cone): The male cone of a cone clutch is the section of the clutch that connects to the gearbox and is machined in the shape of a solid cone over which frictional material is affixed.
3. Flywheel: The female part works as a driving member, and the flywheel is bolted to the engine crankshaft and connected to it.
4. Spring: The purpose of the spring in this clutch is to press the male part against the female part. The clutch is engaged and disengaged using a standard thrust spring positioned behind the male cone.
5. Clutch Shaft: It is connected to the gearbox and uses the clutch to transmit power from the engine. Also, splines on the drive shaft with teeth or ridges that mesh with grooves to impart torque.
6. Throw-out bearing: A throw-out bearing is a component of this clutch that allows the engine to be briefly disengaged while shifting gears in a manual transmission.
7. Friction Lining: The friction lining is applied to the inside surface of the outer cone and the outside surface of the inner cone to ensure that the male and female cones interact smoothly.
8. Clutch pedal: The clutch is engaged and disengaged with the help of a clutch pedal.
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Diagram
How Does Cone Clutch Work?
The working of a cone clutch is less complex and can be easily understood. Because of the springs, when the clutch is engaged, the male part presses against the female part. With its friction surfaces in contact, the male component is totally contained within the female part.
When the engine turns, the female part connected to the engine rotates, and the male part rotates as well due to friction between the cone plates. As a result, the motion is transferred from the driving to the driven member.
When the driver depresses the clutch pedal, the linkage moves the throw-out bearing, which causes the male cone to move away from the female cone, causing the clutch to disengage.
When the driver releases the clutch pedal, the male portion returns to its previous position, allowing the clutch to re-engage.
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Advantages of a Cone Clutch
Below are the benefits of a cone clutch in its various applications:
- The normal force exerted on the contact surfaces is greater than the axial force in this clutch.
- When compared to plate clutches of the same size, it may transfer a lot of torque.
- The clutch requires less effort to operate since the mating surfaces are in the shape of a wedge.
- Compared to other clutch plates, it makes less noise.
Disadvantages of a Cone Clutch
Despite the good benefits of a cone clutch, some limitations still occur. Below are the disadvantages of cone clutches in their various applications:
- The effort required to disengage the clutch will be greater if the cone’s angle is large.
- Even minor wear on the cone surface prevents the clutch from working properly.
- When the cone angle is reduced to roughly 20 degrees, the male cone tends to bind or join the female cone, making it harder to release the clutch.
- Faces should be dressed on a regular basis. Dressing: The act of mending or applying lubricants to keep surfaces smooth for easy operation.
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Conclusion
A cone clutch operates on the principle of friction between conical surfaces to engage and disengage power transmission between the engine and gearbox.
Its higher torque transmission capability compared to a single-plate clutch of the same diameter makes it ideal for low-speed, high-torque applications, such as agricultural machinery, marine equipment, and vintage automobiles.
While not as widely used in modern vehicles due to wear and engagement difficulties, cone clutches remain relevant in specialized mechanical systems where compact and efficient torque transfer is needed.
Frequently Asked Questions (FAQs)
What is a cone clutch?
A cone clutch is a mechanical device that transmits power through conical frictional contact between a male and female cone.
Where are cone clutches used?
Cone clutches are commonly found in:
- Marine transmissions
- Heavy machinery
- Agricultural equipment
- Old/vintage vehicles
What are the advantages of a cone clutch?
- Transmits more torque due to greater frictional area
- Compact design for the same torque as plate-type clutches
- Simple construction
What are the disadvantages of a cone clutch?
- Can be difficult to disengage due to wedging effect
- Higher wear rate
- Not suitable for high-speed or continuous engagement/disengagement systems
How does a cone clutch differ from a plate clutch?
- A cone clutch uses conical surfaces, while a plate clutch uses flat surfaces.
- Cone clutches offer more friction and torque for a given diameter but are less suited to high-speed operations.
Is a cone clutch still used in modern vehicles?
Rarely. It has been replaced by multi-plate and diaphragm clutches in most modern automotive applications due to ease of engagement and better performance at higher speeds.
What is the typical cone angle in a cone clutch?
Usually between 12° to 15°, balancing engagement smoothness with torque transmission.
Where is a cone clutch used?
Cone clutches are used in various manual transmissions, such as synchronizers. They are used in various heavy machines since they can transmit high torque. These clutches are generally used in low-peripheral-speed applications.
Cone clutches are commonly used in power racing boats.
What is the difference between a single-plate clutch and a cone clutch?
In the latter, the spinning disks are mated together, and the cone clutch uses canonical surfaces to transmit torque using friction. Now the single-plate clutch uses a single plate to mate the spinning disks from the driving wheel to the driven wheel in the transmission. again this is done using friction.
What are the three types of clutches?
- Friction clutch. This model of clutch is the most common on cars in circulation.
- Hydraulic clutch. This type of clutch system allows the engine to transmit torque when it reaches a certain engine speed.
- Electromagnetic clutch.
What is the difference between a centrifugal clutch and a cone clutch?
Centrifugal clutches are typically used in small engine applications like go-karts and chainsaws; it engage based on the speed of rotation. A cone clutch is a type that uses conical surfaces to engage and disengage. It’s used in applications where high torque is needed, such as in heavy machinery.