DESIGN 0F CLUTCH
INSTITUTE OF
ENGINEERING AND TECHNOLOGY
DEPARTIMENT OF
MECHANICAL ENGINEERING
MACHINE ELEMENT II GROUP PROJECT
TITLE: DESIGN OF FRICTION CLUTCH
GROUP NAME ID NO.
1.BIRBIRSA BETIE ………………………………………..……………………..0229/15
2 .NURALLA MAHAMMAD………………………………..………………….0897/15
3.BELACHEW ABDETA…………………………………………………………….0189/15
4. GELAYE ASEFA……………………………………………………………………0499/15
5. ALEMU TEMANA………………………………………………………………..0080/15
6. WOKTOLE BEYANA………………………………….…………………………1092/15
SUBMITTED TO: MR. BEYENE
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DESIGN 0F CLUTCH
ACKNOWLEDGMENT
First of all great thanks WOLLEGA UNIVERSTY Department of mechanical Engineering next to
my God helps to do this project. secondly my instructor Mr.BEYANA.G he advice for finish these
project and give more knowledge on machine element course which contain this seminar
project .also I have more Thanks all my friend for giving additional information for us. And for
surprise me when I am tired and all my Dormitory students for contributing any materials for
this project
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DESIGN 0F CLUTCH
ABSTRACT
Clutch is a mechanical device located between a vehicle engine and its transmission and
provides mechanical coupling between the engine and transmission input shaft. Multi plate
clutch is one of the important part in the power transmission systems. Good design of clutch
provides better engine performance. Multi plate clutch is most widely used in ATV's, racing cars
and heavy duty vehicle where high torque transmission required and limited space is available.
The multi plate clutch has modelled in NX 9 software and imported in ANSYS Workbench 15.
The structural analysis has been carried out for friction material clutch plate. The result of
friction materials is based on the static and dynamic analysis, stress and total deformation and
temperature variation and heat flux of the friction plate. Uniform wear theory were used for
the analysis. The Grey Cast Iron and Kevlar 49 friction material are compared based on the total
deformation of the clutch plate to find the better lining material. The Von Mises stress has been
determined by varying the friction surfaces material-Grey Cast Iron and Kevlar 49. After that the
FEM analysis is done for Kevlar friction material. The stresses & deformation obtained for this
friction material is then compared to analysis software result. The analysis is done for worn out
friction disc. By extracting the result we found that Kevlar49 as friction material solve this
difficulty.
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DESIGN 0F CLUTCH
1.1 INTRODUCTION
The clutch is a mechanical device, which is used to connect or disconnects the source of
power from the remaining parts of the power transmission system at the will of operator.
The friction clutch is an important component of any automotive machine. It is a link
between engine and transmission system which conducts power, in form of torque, from
engine to the gear assembly. Mainly there are two types of clutches, one is single plate
clutch which is used for small duty vehicles and the other is multi plate clutch, which has
number of friction plates and steel plate’s assembly used for heavy duty vehicles. The
clutch principle is based on friction. When two friction surfaces are brought in contact with
each other and pressed they are united due to friction between them. If one is revolved the
other will also revolve. The friction between the two surfaces depends upon. Area of the
friction, Pressure applied on them. Generally there are two types of clutches based on type
of contact: 1.Positive clutch, 2.Friction clutch. Desirable Properties for Clutch Plate Lining:
(a) the materials in contact must have a high coefficient of friction. (b) The materials in
contact must high resistance to wear effects, such as scoring, galling, and ablation. (c) The
coefficient of friction should be constant over a specified range of temperatures and
pressures. The material must be resistant to environmental conditions such as moisture,
dust and pressure. (d) The material should possess good thermal properties, high specific
heat capacity, good thermal conductivity and capable of withstanding high temperatures
and contact pressures. (e) The material should possess high shear strength to transfer
torque
1.2 STATEMENT OF PROBLEM
Company has been receiving many complaints about clutch Burst Disc, Damaged Pressure Plate
which resulted from an abnormal amount of clutch slippage/heat. The heat flow was so intense
that the metal could not disperse the heat quickly enough these heat checks are actually small
cracks with raised ridges that are capable of shaving off the facings of the driven disc. The
typical evidence of such a failure was High and low spots on the plate Partial transfer of the
facing material (ceramic or organic) from the driven disc onto the plate. A blue discoloration
throughout the failed part was seen. Previous work has been done on the Grey Cast iron
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DESIGN 0F CLUTCH
friction material clutch plate and dynamic analysis of cracks in compositematerials was carried
out . Static and dynamic analysis of clutch plate had also been done to observe the clutch
before crack and after crack but the crack propagation and growth were not observed.Clutch
failure and damage due to excessive frictional heat and heat fluctuations to the clutch
countermate disc often happens to any type ofautomotive clutches. This situation contribute to
thermal fatigue to thecomponent which cause the clutch countermate disc to crack and deform.
Thislater will create problems such as clutch slip, clutch drag or failure of clutch todisengage
properly and clutch rattling as well as shortening the lifecycle of thecomponent.
1.3 OBJECTIVE OF DESIGN CLUTCH
1.3.1 GENERAL OBJECTIVE
to design friction clutch
1.3.2 SPECIFIC OBJECTIVE
• To know the function of clutch
• To know the construction and working of various types of clutches
• To Draw the different types of friction clutches
• To Overhaul different types of clutches
1.4 SIGNIFICANCE OF FRICTION CLUTCH IN AUTOMOBILE
Clutch is the device which is necessary transmit the power from the engine to
the while of vehicle by engaging the engine to transmission system gradually
without giving jerks to the body of vehicle
They are gradually engaging clutches initial when the disks contact the out put
disk slips ;and gradually picks up the speed.inthe mean time ,the motor
generates enough torque. In case of machine jamming, the out put disc slip,&
the torque would not be transmitted to the motor, thus safe guarding the
motor.
1.5 SCOPE OF CLUTCH
Among different type of friction clutch we are design on single plate cutch in automobile
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DESIGN 0F CLUTCH
1.5.1 Material for Friction Surfaces
The material used for lining of friction surfaces of a clutch should have the following
characteristics :
* During operation of a clutch, most of the work done against frictional forces opposing the
motion isliberated as heat at the interface. It has been found that at the actual point of contact, the
temperature ashigh as 1000°C is reached for a very short duration (i.e. for 0.0001 second). Due
to this, the temperature ofthe contact surfaces will increase and may destroy the clutch.
1. It should have a high and uniform coefficient of friction.
2. It should not be affected by moisture and oil.
3. It should have the ability to withstand high temperatures caused by slippage.
4. It should have high heat conductivity.
5. It should have high resistance to wear and scoring.
The materials commonly used for lining of friction surfaces and their important properties are
shown in the following table.
Considerations in Designing a Friction Clutch
The following considerations must be kept in mind while designing a friction clutch.
1. The suitable material forming the contact surfaces should be selected.
2. The moving parts of the clutch should have low weight in order to minimise the inertia load,
especially in high speed service.
3. The clutch should not require any external force to maintain contact of the friction surfaces.
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DESIGN 0F CLUTCH
4. The provision for taking up wear of the contact surfaces must be provided.
5. The clutch should have provision for facilitating repairs.
6. The clutch should have provision for carrying away the heat generated at the contactsurfaces.
7. The projecting parts of the clutch should be covered by guard.
CHAPTER TWO
2.1 LITERATURAL VIEW OF CLUTCH
Design and Analysis of Friction Clutch Plate using AnsysBy S.Gouseseema begum, and A.
Balaraju investigated experimentally and numerically friction plate using CATIA V5 R20
software and theoretical calculations and also structural analysis has done by using ANSYS
Workbench 14.5. In the study the materials gray cast iron and Kevlar 49 has been selected for
friction plate and structural analysis has been done to find the total deformation, equivalent (von
mises) stress and equivalent elastic strain and concludes that the material Kevlar 49 is more
advantageous than Gray cast iron.
Static And Dynamic Analysis of Clutch Plate With Crack ByN.V.Narasimharao, has Done
Research Work On Investigate How A Crack Propagates And Grows In A Clutch. A Clutch Plate
Is Analyzed For Crack Propagation For Different Materials Aluminum Alloy 6061, Aluminum
Alloy 7475, Composite Materials S2 Glass And Kevlar. Theoretical Calculations Are Done To
Determine Stress Intensity Factor, Crack Extension Force, Crack Opening Displacement. . From
Dynamics And Fracture Mechanics, It Is Well Known That Accelerated Crack Nucleation And
Micro-Crack Formation In Components Can Occur Due To Various Reasons, Such As Transient
Load Swings, Higher Than Expected Intermittent Loads, Or Defective Component Materials.
Normal Wear Causes Configuration Changes That Contribute To Dynamic Loading Conditions
That Can Cause Micro Crack Formation At Material Grain Boundaries In Stress Concentrated
Regions (Acute Changes In Material Geometry). So, Finally They 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
Static and Dynamic Analysis of Single Plate Clutch By B.Sreevani ,and M.Murali Mohan
explained that present used material for friction disc is Cast Iron and aluminum alloys. In this
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thesis analysis is performed using composite materials and concluded that by analytical and
theoretical results, E Glass Epoxy is better.
Design Modification & Failure Analysis of a Driven Plate/Friction Plate of a Clutch using FEA
ByMarella. Veerendra, Gowthamtham Reddy, Vudumula,and K. N. D. MalleswaraRao[4]
International Journal of Advance Engineering and Research Development (IJAERD) Volume 3,
Issue 2, February -2016, e-ISSN: 2348 - 4470, print-ISSN: 2348-6406
@IJAERD-2016, All rights Reserved 284
investigated on a Friction plate of a clutch using FEA and from the analysis result it was found
that in the actual side plate the maximum value of stress is very near to the theoretical endurance
limit. It was proofed experimentally. A Literature Review on Failure in Single Plate Clutch
System By K.C.Lathiya,N.P.Badola2,C.L.Undhad,and B.D.Dhamecha[5] , studied on failure of
single plate clutch system and from results obtained it was concluded that failure of clutch and its
damage due to excessive frictional heat and heat fluctuations in the clutch counter-mate disc
usually occurs in all type of automotive clutches.
DESIGN FAILURE MODES AND EFFECTS ANALYSIS (DFMEA) OF AN ALL-TERRAIN
VEHICLE By SidharthaPattnaik[6], explained about DFMEA (Design Failure Modes and
Effects Analysis), technique which is used to list out all modes of failure for various components
of the ATV, its causes, effects and ways of preventing it.
Effect of Band Contact on the Temperature Distribution for Dry Friction By Oday I. Abdullah,
and J. Schlattmann[7], Investigated Heat Generation Due To Friction Using Finite Element
Method to avoid the failures due to the high thermal stresses. Analysis has been completed using
a three dimensional model to simulate the thermo-structural coupling in automotive clutches
using Ansys.
Static/kinetic Friction behaviour of a Clutch Facing Material: Effects of Temperature and
Pressure By A.Chaikittiratana, S. Koetniyom,and S. Lakkam[8] Investigated The feasibility of
applying a simple and cost effective sliding friction testing apparatus to study the friction
behaviour of a clutch facing material, effected by the variation of temperature and contact
pressure.. It was found that the method used in this work was able to give a convenient and cost
effective measurement of friction coefficients and their transitions of a clutch facing material.
The obtained results will be useful for the development process of new facing materials
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DESIGN 0F CLUTCH
Flowpath Optimization of Wet Multi-plate Friction Clutch By Qing Wang, TengjiaoLin , Li Pan
and QuanchengPeng [9] explained that by optimizing internal flow path of wet friction clutch
heat generated can be reduced significantly. The optimized structure of flow path is obtained,
and the rationality of optimization result is verified. 3
CHAPTER THREE
DESIGN ANALYSIS
CHAPTER FOUR
4.1 RESULTS AND CONCUSION
CONCLUSION
Static Structural, modal and fatigue analysis is done for multi plate clutch using the properties of
the three materials. Outer material is steel and Materials used for friction plate are varied Cast
iron, Cork and Asbestos. Comparison is done for above materials to validate better friction
material for multi plate clutch. By observing static analysis results, the stress values for all
materials are less than that of their respective yield stress values. The deformation and stress
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DESIGN 0F CLUTCH
values are less for Cast Iron and Asbestos is used. By observing modal analysis results, the
deformation is less for Cast Iron but the frequencies are less when Cork is used. Since the
frequencies are lesser, the vibrations in the clutch will be reduced when cork is used. By
observing fatigue analysis results, the life is more for Cast Iron but the damage is more for Cork
and Asbestos. The clutch will be failed if the appliedload is multiplied with the damage value.
Since the damage value is more for Cork and Asbestos, the clutch when both the materials are
used will fail at very larger loads. So it can be concluded that using Cork for friction plate is
better.
RECOMANDATION
REFERENCES
[1] S.Gouseseema begum, and A. Balaraju, “Design and Analysis of Friction Clutch Plate using
Ansys”, International Journal of Advanced Engineering Research and Science (IJAERS), Vol-
2,pp-1-5 Issue-5, May- 2015. [2] N.V.Narasimharao.L,andCh.Chandrara, “Static and Dynamic
Analysis of Clutch Plate With Crack”, IJRMET, Vol. 4,pp123-125 Nov 2013 - Apri 2014. [3]
B.Sreevani ,andM.Murali Mohan, “Static and Dynamic Analysis of Single Plate Clutch”,
International Journal of Innovative Research in Science, Engineering and Technology, Vol. 4,
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DESIGN 0F CLUTCH
pp-8408-7418, September 2015 [4] Marella. Veerendra, Gowthamtham Reddy, Vudumula,and
K. N. D. MalleswaraRao, “Design Modification & Failure Analysis of a Driven Plate/Friction
Plate of a Clutch using FEA.”, IJERA , Vol. 4, pp.148-150 October 2014. [5]
K.C.Lathiya,N.P.Badola2,C.L.Undhad,andB.D.Dhamecha, “ A Literature Review on Failure in
Single Plate Clutch System”, IJSRD, Vol.2,pp-361-363, Oct 2014. [6] SidharthaPattnaik, “
DESIGN FAILURE MODES AND EFFECTS ANALYSIS (DFMEA) OF AN ALL-TERRAIN
VEHICLE”, International Journal of Research in Engineering and Technology,Vol-4,pp-339-
345,june-2015 [7] Oday I. Abdullah, and J. Schlattmann, “Effect of Band Contact on the
Temperature Distribution for Dry Friction”, International Journal of Mechanical, Aerospace,
Industrial, Mechatronic and Manufacturing Engineering ,Vol:6,pp1807-1817 [8]
A.Chaikittiratana, S. Koetniyom,and S. Lakkam, “Static/kinetic Friction behaviour of a Clutch
Facing Material: Effects of Temperature and Pressure”,International Journal of Mechanical,
Aerospace, Industrial, Mechatronic and Manufacturing Engineering,vol-6,pp-1048-1051,2012.
[9] Qing Wang, TengjiaoLin , Li Pan and QuanchengPeng, “Internal Flowpath Optimization of
Wet Multi-plate Friction Clutch”, International Conference on Mechatronics, Robotics and
Automation ICMRA ,pp-620-623,201
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