DYNAMIC ANALYSIS OF SINGLE PLATE CLUTCH USING DIFFERENT FRICTION

MATERIALS

PRESENTED BY

B.ARUN

GUIDED BY

Dr. S.JEYAKUMAR M.E., PhD

INTRODUCTION• Clutch is a mechanical device located between a vehicle

engine and its transmission and provides mechanical coupling between the engine and transmission input shaft. Clutch system comprise of flywheel, clutch disc plate and friction material, pressure plate, clutch cover, diaphragm spring and the linkage necessary to operate the clutch.

• The clutch engages the transmission gradually by allowing a certain amount of slippage between the flywheel and the transmission input shaft. However, the slipping mechanism of the clutch generates heat energy due to friction between the clutch disc and the flywheel.

• Clutch works on the principle of friction. When two friction surfaces are brought in contact with each other and pressed they are united due to the friction between them.

• The friction between the two surfaces depends upon the area of the surfaces, pressure applied on them and co-efficient of friction of the surface material. The two surfaces can be separated and brought into contact when required.

• One surface is considered as a driving member the other as a driven member. The driving member is kept rotating, when the driven member is brought in contact with the driving member it also rotates. When the driven member is separated from the driving member it does not rotate. This is the principle on which the clutch operates.

OBJECTIVE

• To carry out the dynamic analysis of friction plate using different friction materials.

• Using sintered metals we can reduce the wear of friction plate.• The stress and deformation is to be obtain for the different

materials and compare their results.

PROPERTIES

Friction MaterialAgainst Steel or Cl

Coefficient of Friction

Maximum Pressure

kpa

Maximum Temprerature

oC

Sintered metal 0.15-0.45 1030-2070 232-677

LITERATURE REVIEW

s.no Project title & author Description

1 Design and finite element analysis of an automotive clutch assemblyRajesh Purohit, Pooja Khitoliya and Dinesh Kumar Koli.

In the present work a friction clutch assembly was designed. It consist of three parts viz. clutch plate, pressure plate and diaphragm spring. The material assignment is as follows: clutch plate- structural steel, pressure plate- cast iron GS-70-02 and diaphragm spring- spring steel. The friction material assumed is molded asbestos opposing cast iron/ steel surface..Finite element analysis was performed in ANSYS software. The plots for Equivalent von-Mises stress, total deformation and factor of safety were calculated and analyzed. The finite element analysis showed that the designed friction clutch assembly is safe.

s.no Project title & author description

2 Design and analysis of clutch using sintered iron as a friction materialMamta G. Pawar, Monarch K. Warambhe and Gautam R. Jodh

In this project after designing of clutch disc, the analysis is done by varying the friction material & following conclusion is drawn. The analysis is done for worn out friction disc. The stresses using Kevlar as a friction material & sintered iron is near about same. Torque transmission capacity of sintered-iron friction material is 350 to 400N which is more than Kevlar. Total deformation in Kevlar material is less than sintered-iron friction material. Sintered-iron material can sustain higher temperature. By applying the maximum force i.e, 220 N of the friction plate of single plate clutch, after analytical calculations & software analysis the following observations can be obtained.

S.No Project title & author Description

3 Static structural analysis of mutiplate clutch using different friction materialAnil Jadhav, Gauri Salvi, Santosh Ukamnal and Prof.P.Baskar

In this project, a 3D model of multi-plate clutch and its assembly has been done using Pro-E software packages. Structural analysis on clutch plate has been carried out using ANSYS workbench for copper, cork and SA92 as friction lining materials. Ultimately, from this analysis it can be concluded that, on the strength basis, SA92 is more suitable and quite better friction material than copper and cork for same rated torque.

S.No Project title & author Description

4 Dynamic analysis of crack in composite materialK.Praveen, rakesh jalla

In this paper, to investigate how a crack propagates and grows in a clutch. The finite element program ANSYS is used to simulate crack growth and to compute the stresses and the stress-intensity factor. By observing the analysis results, the stress values are more for composite materials and when the crack is started the composite materials, stress values increases more than the condition of no crack so the composite materials fails faster once the crack propagates.So we can conclude that if the crack propagates in the composite materials, they tend to fail faster than aluminum alloys thereby reducing their life. So care should be taken for composite materials not to get the crack.

S.No Project title & author Description

5 Static/kinetic Friction behaviour of a Clutch Facing Material: Effects of Temperature and Pressure

In this project, the feasibility of applying a simple and cost effectivesliding friction testing apparatus to study the friction behavior of aclutch facing material, effected by the variation of temperature andcontact pressure, was investigated. It was found that the method usedin this work was able to give a convenient and cost effectivemeasurement of friction coefficients and their transitions of a clutchfacing material.

S.No

Project title & author Description

6 Optimizing friction behavior of clutch facings using pin-on-disk testKhamlichi A, Bezzazi M.

In this project, a rational approach based on Taguchi technique and Pin-on-disk test is used in order to study the friction coefficient behavior of clutch facings as function of material formulation.Clutch facings investigated in this study are of non asbestos organic type. Experiments were designed according to the orthogonal array L8 where the chosen factors are temperature and sliding speed.

S.No Project title & author Description

7 Analysis of density of sintered iron powder component using the response surface methodPrasanta kumar bardhan, suprs patra and goutam sutradhar

In engineering application is largely dependent on the development of higher density materials and improved mechanical properties. An experimental investigation have been undertaken in order to understand the variation of density with respect to the variation of process parameters such as compaction load, sinter temperature and sintering time. In this project, a detail microstructure analysis has been made which confirms that the density of the P/M product considerably increases with the increase in compaction load, sintering temperature and sintering time. The results obtained have been analyzed through the response surface model.

S.No

Project title & author Description

8 THE EFFECT OF BORON LIQUID PHASE SINTERING ON PROPERTIES OF ni-, mo-, cr- ALLOYED STURUCTURAL STEELS M. Selecka, A. Salak and H. Danninger

In this project, they concluded that Boron is evaluated as the best sintering enhancing element in terms of identifying the iron-based materials by formation the liquid phase. The influence of boron addition (up to 0.6%) on the density, microstructure formation and the strength of the different pre-alloyed powders. Micro-structural analysis showed an interaction of boron with matrix alloying elements. The formation of borides caused the increase of micro-hardness and hardness values of matrix. The higher density and micro-hardness expressed in higher strength of materials. The material systems based on iron, Ni-, Mo- and Cr- pre-alloyed powders with boron addition up to 0.6% after sintering at 1200 ◦C for 60 min in hydrogen were investigated.A positive effect of boron liquid phase sintering on the properties of Ni-, Mo- and Cr-alloyed material systems was demonstrated.

S.No

Project title & author Description

9 Hoganas “(SINTERED IRON BASED MATERIALS)”

Hoganas has developed a variety of materials containing Mo in combination with Ni or Cu, or both Ni and Cu, which have proven very successful in the production of structural parts for high-strength and high-accuracy applications. Some of these materials are homogenous alloys with the trade-name Astaloy, but most of them are partially pre-alloyed non-segregable powder mixes with the trade-name Distaloy.Mixed with appropriate amounts of graphite, Astaloy- and Distaloy-materials, yield high strength properties, show good dimensional stability during sintering, and respond very well to subsequent heat-treatment.

S.No

Project title & author Description

10 Experimental characterization of frictional behaviour of clutch facings using Pin-on-disk machineM.Bezzazi, A. Khamlichi

During the clutch engagement, sliding contact occurs between the pair of clutch facings mounted on the friction disk and the counter faces belonging to the flywheel and the pressure plate. The transmitted torque is proportional to the overall coefficient of friction which depends essentially on temperature, normal pressure load and relative sliding velocity. In this work, performance of the friction coefficient is investigated experimentally. Samples of a commercial clutch facings material have been tested using a Pin-on-disk apparatus. When the previous three parameters are preset constant, this machine provides automatic acquisition of friction coefficient and wear measurements. The obtained results are compared with the classical SAE J661a standard test.

PROBLEM CHARACTERISTICS CAUSES

Distortion Facings out of flatness afterhigh operating temperature

Unsuitable friction material

Reduced performance Decrease in coefficient offriction giving apermanent loss in performance

Excess oil or grease onfriction material or on theopposing surface

Burstfailure Material splitting andremoved from the spinnerplate

High stresses on facingswhen working at highSpeeds

Crushing Loss of friction material atthe ends of a band

Crushing and excessive wear Of the friction material

PROBLEM DEFINITION

• The problems with a slipping clutch are that the friction material’s coefficient of friction is affected by heat. As temperature goes up the coefficient of friction goes down, and the total clutch capacity decreases. Heat reduces friction, which increases slippage, which increases heat the cycle becomes self-limiting when the torque capacity of the clutch drops to zero.

• On the flip side, organic material does have less heat capacity than most other common lining material and it wears fast than some other. The heat created by a Kevlar disc slipping against flywheel and will burn the flywheel.

• The clutch engages the transmission gradually by allowing a certain amount of slippage between the flywheel and the transmission input shaft. However, the slipping mechanism of the clutch generates heat energy due to friction between the clutch disc and the flywheel.

• At high sliding velocity, excessive frictional heat is generated which lead to high temperature rise at the clutch disc surface, and this causes thermo-mechanical problems such as thermal deformations and thermo-elastic instability which can lead to thermal cracking, wear and other mode of failure of the clutch disc component.

• By using Iron - Copper - Nickel - Molybdenum – Carbon, Hoganas has developed a variety of materials containing Mo in combination with Ni or Cu, or both Ni and Cu, which have proven very successful in the production of structural parts for high-strength and high-accuracy applications. Such as Distaloy SA, Distaloy AB, Distaloy SE, Distaloy AE.

• Dynamic analysis is carrying out to determine the stress and deformation for different materials.

METHODOLOGY

SELECTION OF FRICTION MATERIALS

MODELLING OF FRICTION PLATE

DYNAMIC ANALYSIS OF FRICTION PLATE USING DIFFERENT MATERIALS TO DETERMINE STRESS

AND DEFORMATION

CALUCLATION AND COMPARISON

Selection of friction materials

• Distaloy SA is based on the sponge iron grade SC100.26 to which 1.75%Ni, 1.5%Cu and 0.5%Mo have been diffusion-bonded. Being based on sponge iron powder, this material has high green-strength. Mixed with appropriate amounts of graphite it yields high strength after sintering and responds well to subsequent heat-treatment.

 • Distaloy AB has the same chemical composition as Distaloy SA

but is based on the atomized iron powder grade ASC100.29. Being based on atomized iron powder, it has high compressibility. Mixed with appropriate amounts of graphite it yields high strength after sintering and responds well to subsequent heat-treatment.

CONT..

• Distaloy SE is based on the sponge iron grade SC100.26 to which 4%Ni, 1.5%Cu and 0.5%Mo have been diffusion-bonded. Being based on sponge iron powder, it has high green-strength. Mixed with appropriate amounts of graphite it yields high strength after sintering and responds very well to subsequent heat-treatment.

• Distaloy AE has the same chemical composition as Distaloy SE but is based on the atomized iron powder grade ASC100.29. Being based on atomized iron powder, it has high compressibility. Mixed with appropriate amounts of graphite it yields high strength after sintering and responds very well to subsequent heat-treatment.

• Properties of distaloy-materials

Modeling of friction plate• Solid modeling of friction plate is to be model by using

catia v5 software TATA SFC-407 specification.Dynamic analysis• The design of products that need to survive impacts or short-

duration high-pressure loadings can be greatly improved with the use of ANSYS explicit dynamic solutions.

• By explicit dynamic analysis stress and deformation is to be obtained by different materials and compare with the results.

Reference• Rajesh Purohit, Pooja Khitoliya, Dinesh Kumar Koli, “Design

and finite element analysis of an automotive clutch assembly” Procedia Materials Science 6 (2014) 490 – 502.

• Aravind vadiraj, “Engagement characteristics of a friction pad for commercial vehicle clutch system” Sadhan Vol. 35, Part 5, October 2010, pp. 585–595. © Indian Academy of Sciences.

• Oday, Abdullah, Josef Schlattmann, “Vibration Analysis of the Friction clutch Disc Using Finite Element Method” Advances in Mechanical Engineering and its Applications (AMEA) Vol. 1, No. 4, 2012, ISSN 2167-6380.

• Dr.Prafull. S. Thakare, “MODELLING AND ASSEMBLY OF SINGLE PLATE

• FRICTION CLUTCH OF AN AUTOMOBILE” Indian Streams Research Journal Vol.2,Issue.II/Marchl; 2012.

• Mamta G. Pawar, Monarch K. Warambhe, Gautam R. Jodh, “ Design and Analysis of Clutch Using Sintered Iron as a Friction Material” International Journal of Innovative Technology and Exploring Engineering (IJITEE) ISSN: 2278-3075, Volume-3, Issue-7, December 2013.

• K.Praveen, Rakesh Jalla, “DYNAMIC ANALYSIS OF CRACK IN COMPOSITE MATERIAL” IJREAT International Journal of Research in Engineering & Advanced Technology ISSN: 2320 – 8791 Volume 1, Issue 4, Aug-Sept, 2013.

• Prasanta Kumar Bardhan, Suprs Patra, Goutam Sutradhar, “ANALYSIS OF DENSITY OF SINTERED IRON POWDER COMPONENT USING THE RESPONSE SURFACE METHOD” Materials Sciences and Applications, 2010, 1, 152-157 doi:10.4236/msa.2010.13024 published Online August 2010 (http://www.SciRP.org/journal/msa)

• M. Selecka, A. Salak, H. Danninger, “THE EFFECT OF BORON LIQUID PHASE SINTERING ON PROPERTIES OF Ni-, Mo-, Cr- ALLOYED STURUCTURAL STEELS” Journal of Materials Processing Technology 143–144 (2003) 910–915.

• Hoganas , “SINTERED IRON BASED MATERIALS” http://riad.pk.edu.pl/~mnykiel/iim/KTM/MP/DOWNLOAD/pdf/CHAPT09.PDF

 • Fred K. Geitner and Heinz P. Bloch, “Maximizing Machinery

Uptime”.

 • “ClutchFaultyDiagnosisThomas”

http://thomasbct.com.au/wp-content/uploads/2009/10/ClutchFaultyDiagnosisThomas.pdf

 • Robert Bowen, “How to Rebuild and Modify Your Manual

Transmission”

• A. Chaikittiratana, S. Koetniyom, S. Lakkam ”Static/kinetic Friction behaviour of a Clutch Facing Material: Effects of Temperature and Pressure”

• A. Khamlichi, M. Bezzazi, A. Jabbouri, P. Reis and J. P. Davim. “Optimizing friction behaviour of clutch facings using pin-on-disk test”

• M.Bezzazi, A. Khamlichi “Experimental characterization of frictional behaviour of clutch facings using Pin-on-disk machine”

THANK YOU