Design Single Plate Clutch Disc

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Design Single Plate Clutch Disc
System Analysis and Design (Dire Dawa University)
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Design of Single Disc Plate
Acknowledgment
First, I would like to thank God. Next to express my gratitude to all those who gave me the
possibility to complete my design projects. And I feel really obliged by guide, support and
Supervise provided by instructor Tamana D. (MSc), Design and solid mechanics chair
Finally, yet importantly, I would like to express my heartfelt thanks to Mr. Hailemikal Solomon
who guide me how I get the sources and wishes for the successful completion of this project.
PREPARED BY: SELEMUN WELDEDAWIT R/1362/06 I

Abstract
Clutch system is the main systems inside a vehicle. 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.
In design of the friction clutches of automobiles, knowledge on the thermo-elasticity a priori is

very informative in the initial design stage. Especially, the precise prediction technique of
maximum structural stress should be requested in design of mechanical clutches for their
durability and compactness. In this study, an efficient and reliable analysis technique for the
design of the mechanical clutches by using computer modeling and numerical method is
developed. This work contains stress analysis of single plate clutch of the automobile, in which
the stresses and forces developed in the clutch is tried to reduce with the help of software
approach. The detail study of clutch and modeling of clutch is done in Catia V5R20 software.
PREPARED BY: SELEMUN WELDEDAWIT R/1362/06 II

Nomenclatures
⮣ r1 = Outer radius of the friction plate, and
r2 = Inner radius of the friction plate.
⮣ T = Torque transmitted by the clutch,
⮣ p = Intensity of axial pressure with which the contact surfaces are held
r = Mean radius of the friction face, and
μ = Coefficient of friction.
⮣ R = Mean radius of the friction lining, and
R
⮣ b = Face width of the friction lining =
4
⮣ D = Mean diameter of the spring, an
⮣ d = Diameter of the spring wire.
⮣ n = Number of active coils,
⮣ G = Modulus of rigidity for the spring material = 84kN 2 ,
mm
⮣ W = Axial load on the spring,
⮣ τ = Maximum shear stress induced in the wire,
⮣ C = spring index = 6
⮣ p = Pitch of the coils, and
⮣ δ = Deflection of the spring, as a result of an axial load W.
PREPARED BY: SELEMUN WELDEDAWIT R/1362/06 III

List of Figure
Figure 1: Main Part of Clutch System.............................................................................................2
Figure 2: Clutch components..........................................................................................................4
Figure 3: flywheel............................................................................................................................5
Figure 4: friction or disc clutch.......................................................................................................6
Figure 5: Assemble of internal parts of clutch.................................................................................7
Figure 6: Clutch with diaphragm spring..........................................................................................8
Figure 7: Single Disc Plate Clutch.................................................................................................12
Figure 8: Forces on a disc clutch...................................................................................................13
Figure 9: Plate................................................................................................................................19
Figure 10: Spring...........................................................................................................................20
Figure 11: Friction surface.............................................................................................................21
Figure 12: Assembly......................................................................................................................22
List of Table
Table 1: Result for all component of single plate clutch disc........................................................24
Table 2: Properties of materials commonly used for lining of friction surfaces...........................28
Table 3: Standard wire gauge (SWG) number and corresponding diameter of spring wire.........28
PREPARED BY: SELEMUN WELDEDAWIT R/1362/06 IV

Table of Contents
Acknowledgment..............................................................................................................................i
Abstract............................................................................................................................................ii
Nomenclatures................................................................................................................................iii
List of Figure..................................................................................................................................iv
List of Table....................................................................................................................................iv
Chapter-One.....................................................................................................................................1
1.1 Introduction............................................................................................................................1
1.2 Function of clutch..................................................................................................................1
1.3 Working Principle of Single Plate Clutch Disc.....................................................................1
1.4 Characteristics of a good clutch.............................................................................................2
1.5 Types of Clutches..................................................................................................................3
1.6 Component of clutch..............................................................................................................4
1.7 Objective................................................................................................................................8
1.7.1 General objective............................................................................................................8
1.7.2 Specific objective............................................................................................................8
1.8 Problem of Statement............................................................................................................9
1.9 Methodology..........................................................................................................................9
Chapter-Two..................................................................................................................................10
2.1 Literature Review................................................................................................................10
Chapter-Three................................................................................................................................11
3.1 Material Selection................................................................................................................11
Chapter-Four..................................................................................................................................12
4.1 Design Analysis...................................................................................................................12
4.2.1 Design of Single Disc Plate Clutch..............................................................................12
4.2.2 Considerations in Designing a Friction Clutch.............................................................12
4.2.3 Design Specification.....................................................................................................13
4.2.4 Design of the shaft........................................................................................................13
4.2.5 Design Mean radius and face width of the friction lining............................................13
4.2.6 Design Outer and inner radii of the clutch plate...........................................................15
4.2.7 Design for Maximum, minimum and average intensity of pressure............................15
4.2.8 Design for the spring....................................................................................................17
PREPARED BY: SELEMUN WELDEDAWIT R/1362/06 V
4.2 Detail Drawing.....................................................................................................................19
4.2.1 Component....................................................................................................................19

4.2.2 Assembly......................................................................................................................21
Chapter-Five..................................................................................................................................24
5.1 Result and Discussion..........................................................................................................24
5.1.1 Results...........................................................................................................................24
5.1.2 Discussion.....................................................................................................................25
Chapter-six.....................................................................................................................................26
6.1 Conclusion...........................................................................................................................26
Reference.......................................................................................................................................27
Appendix........................................................................................................................................28
PREPARED BY: SELEMUN WELDEDAWIT R/1362/06 VI

Chapter-One
1.1 Introduction
A clutch is a machine member used to connect a driving shaft to a driven shaft so that the driven
shaft may be started or stopped at will, without stopping the driving shaft. The use of a clutch is
mostly found in automobiles. A little consideration will show that in order to change gears or to
stop the vehicle, it is required that the driven shaft should stop, but the engine should continue to
run. It is, therefore, necessary that the driven shaft should be disengaged from the driving shaft.
The engagement and disengagement of the shafts is obtained by means of a clutch which is
operated by a lever.
1.2 Function of clutch

🡆 To permit engagement or disengagement of a gear when the vehicle is stationary and the
engine is running.
🡆 To transmit the engine power to the road wheels smoothly without jerks to the
transmission system while setting the vehicle in motion.
🡆 To permit the engaging of the gears when the vehicle is in motion without damaging the
gear wheels.
1.3 Working Principle of Single Plate Clutch Disc

A single plate clutch consists of a clutch plate whose both sides are faced with a frictional
material. It is mounted on the hub which is free to move axially along the spline of the driven
shaft. The pressure plate and flywheel rotate with the engine crankshaft or driving shaft. The
pressure plate pushes the clutch plate towards the flywheel by a set of strong springs which are
arranged radially inside the body. When the clutch is engaged, the power is flows from the
engine to the rear wheels through the transmission system and the vehicle moves. When the
clutch is disengaged, the power is not transmitted to the rear wheels and the vehicle stops while
the engine is still running. The clutch is disengaged when starting the engine, when shifting the
gears, when stopping the vehicle and when idling the engine. The clutch permits the gradual
taking up of the load. It prevents jerky motion of the vehicle.
PREPARED BY: SELEMUN WELDEDAWIT R/1362/06 1

The axial pressure exerted by the spring provides a frictional force in the circumferential
direction when the relative motion between the driving and driven members tends to takes place.
If the torque due to this frictional force exceeds the torque to be transmitted, then no slipping
takes place and the power is transmitted from the driving shaft to the driven shaft. Figure 4
shows the main parts of clutch system.
Figure 1: Main Part of Clutch System
1.4 Characteristics of a good clutch

 It must be simple to operate the clutch.
 Power must be transmitted smoothly.
 Once clutch is engaged, it must transmit power without slipping.
 It must disengage accurately and quickly.
 It must have good heat radiation properties.
 It must be well balanced during rotation.
 It must have long trouble-free life.
 It must be easy to inspect, adjust and repair.

1.5 Types of Clutches
1. Positive clutches
The positive clutches are used when a positive drive is required. The simplest type of a positive
clutch is a jaw or claw clutch. The jaw clutch permits one shaft to drive another through a direct
contact of interlocking jaws. It consists of two halves, one of which is permanently fastened to
the driving shaft by a sunk key. The other half of the clutch is movable and it is free to slide
axially on the driven shaft, but it is prevented from turning relatively to its shaft by means of
feather key. The jaws of the clutch may be of square type.
A square jaw type is used where engagement and disengagement in motion and under load is
not necessary. This type of clutch will transmit power in either direction of rotation. The spiral
jaws may be left-hand or right-hand, because power transmitted by them is in one direction only.
This type of clutch is occasionally used where the clutch must be engaged and disengaged while
in motion. The use of jaw clutches are frequently applied to sprocket wheels, gears and pulleys.
In such a case, the non-sliding part is made integral with the hub.
2. Friction clutches
A friction clutch has its principal application in the transmission of power of shafts and
machines which must be started and stopped frequently. Its application is also found in cases in
which power is to be delivered to machines partially or fully loaded. The force of friction is used
to start the driven shaft from rest and gradually brings it up to the proper speed without excessive
slipping of the friction surfaces. In automobiles, friction clutch is used to connect the engine to
the drive shaft. In operating such a clutch, care should be taken so that the friction surfaces
engage easily and gradually bring the driven shaft up to proper speed. The proper alignment of
the bearing must be maintained and it should be located as close to the clutch as possible. It may
be noted that.
⭢ The contact surfaces should develop a frictional force that may pick up and hold the
load with reasonably low pressure between the contact surfaces.
⭢ The heat of friction should be rapidly *dissipated and tendency to grab should be at a
minimum.
⭢ The surfaces should be backed by a material stiff enough to ensure a reasonably uniform
distribution of pressure.

Types of Friction Clutches
Though there are many types of friction clutches, yet the following are important from the
subject point of view:
1. Disc or plate clutches (single disc or multiple disc clutch),

2. Cone clutches, and
3. Centrifugal clutches.
1.6 Component of clutch

An engine clutch consists primarily of four parts:
Fly wheel
Friction/clutch disc
Pressure plate assembly and
Release/control mechanism
Figure 2: Clutch components
A. Clutch Housing
The clutch housing is a stamped or cast metal part, which houses the clutch and connects the
transmission housing to the back of the engine.

B. Flywheel
The flywheel is a fairly large wheel that is connected to the crankshaft. The clutch assembly is
mounted to the flywheel, sandwiching the clutch disk in between. It also provides a friction
surface to the clutch. A bearing, called the "pilot bearing" is installed in a hole in the center of
the flywheel. This lubricated bearing, either a ball bearing or a bronze bushing, is used to support
one end of the clutch shaft, which is also the transmission input shaft. The clutch disc is clamped
and held against the flywheel by the spring action of the pressure plate. The face of the flywheel
is precision machined to a smooth surface.
Figure 3: flywheel
Three common uses of a flywheel include
 They provide continues energy when the energy source is discontinues.

 They deliver energy at rates beyond the ability of a continue energy source.
 They control the orientation of a mechanical system.
C. Friction or disc clutch
The clutch disc, also called friction disc, consists of a splined hub and a round metal plate
covered with friction material (lining). The clutch disc friction material also called disc lining
or facing, is made of heat-resistant asbestos, cotton fibers, and copper wires woven or molded
together. Grooves are cut into the friction material to aid cooling and release of the clutch disc.
Rivets are used to bond the friction material to both sides of the metal body of the disc.
The splines in the center of the clutch disc mesh with the splines on the input shaft of the manual
transmission. This makes the input shaft and disc turn together. However, the disc is free to slide
back and forth on the shaft.

Clutch disc is provided with torsion springs, to absorb the torsional vibration of the crank shaft
and some of the vibration and shock produced by clutch engagement. They are small coil springs
located between the hub and the steel disk. When the clutch is engaged, the pressure plate jams
the stationary disc against the spinning flywheel. The torsion springs compress and soften, as the
disc first begins to turn with the flywheel.
Figure 4: friction or disc clutch
To make clutch engagement as smooth as possible and eliminate chatter, the steel disk is slightly
twisted (cushion spring), to make the engagement gradual as the disk flattens out.
D. Pressure Plate assembly: Pressure plate assembly with coil
spring: The main parts of a pressure plate assembly are:
 Pressure plate cover

 Pressure springs (coil springs)
 Pressure plate
 Release levers
 Eye bolt assembly.
The pressure plate cover is bolted to the flywheel. Its main purpose is to hold the assembly
together. Holes around the outer edge of the cover are for bolting the pressure plate to the
flywheel. The pressure plate springs are pre compressed between the pressure plate and cover.

The face of the pressure plate is a large, flat ring that contacts the clutch disc during clutch
engagement.
Figure 5: Assemble of internal parts of clutch
The backside of the pressure plate has pockets for the coil springs and brackets for hinging the
release levers. During clutch action, the pressure plate moves back and forth inside the clutch
cover. The release levers are hinged inside the pressure plate to pry on and move the pressure
plate face away from the clutch disc and flywheel. The eye bolt(fulcrum point of the release
lever) is screwed in to a flange nut, which is locked by the lock nut. This arrangement provides
the clutch release lever adjustment.
Small clip-type springs fit around the release levers to keep them rattling when fully released.
E. Pressure plate assembly with Diaphragm type spring:
The main difference between it and the coil spring type is that a one-piece conical (diaphragm)
spring is used instead of coil springs. The diaphragm spring is a large, round disc of spring steel,
which has a solid outer ring and individual tapered fingers. The tapered fingers also serve as
release levers.

Figure 6: Clutch with diaphragm spring
The diaphragm spring is held to the pressure plate by three retracting springs. A pivot ring is
located at each side of the diaphragm spring about one inch from the outer rim and function as a
pivot during the diaphragm spring action.
Application of pressure at the inner section of the diaphragm will cause the outer rim to move
away from the flywheel and draw the pressure plate away from the clutch disc, disengaging the
clutch.
1.7 Objective
1.7.1 General objective
 To Design the effective Single Plate Clutch Disc.
1.7.2 Specific objective

🡆 To Design the component and dimension for Single Plate Clutch Disc.
🡆 To estimate the analysis by using ANSYS 16 software.
🡆 To draw the drawing by using SOLIDWORK 2016 software.
🡆 To calculate the maximum, minimum and average pressure of friction plate.

1.8 Problem of Statement
A single disc or plate clutch consists of a clutch plate whose both sides are faced with a frictional
material. It is mounted on the hub which is free to move axially along the splines of the driven
shaft. And a multiple disc clutch, may be when a large torque is to be transmitted. The inside
discs (usually of steel) are fastened to the driven shaft to permit axial motion (except for the last
disc). The multiple disc clutches are extensively used in motor cars, machine tools etc.
With respect to comparing multiple clutch, the single plate clutch is preferable to use or to design
when a small torque is to be transmitted or in a mini automobile, since the parts of single plate
clutch is fewer than multiple clutch. Therefore, the cost of multiple clutch is expensive than the
single plate clutch. In the case of that the single plate clutch is preferable or important in a small
automobile (when a small torque is to be transmitted).
1.9 Methodology
Internet source are vital to this design project because some of the source or reference were
found from internet websites.
In project various methods is used to collect data and information.
Different softcopy books.

International journal.
Asking different people.
Visualizing from animation videos and 3D drawing views.
Then after designing the parts by theoretical calculation, the design is modeled by using the
SOLIDWORK 2016 software.

2.1 Literature Review Chapter-Two

Static And Dynamic Analysis of Clutch Plate with Crack by N.V.Narasimharao [2] 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, and 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.

Chapter-Three
3.1 Material Selection
The material used for lining of friction surfaces of a clutch should have the following
characteristics:
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.
Spring materials
Spring is defined as the elastic machine element that deflects under the action of load and
returns to its original shape when the load is removed. The important functions and
applications of springs are used to:
⭢ Absorb shocks and vibrations

⭢ Store energy
⭢ Measure force
⭢ Apply force and controlling motion
Selection of material for spring wire depends on the following factors:
1) Load acting on the spring.

2) The range of the stress through which spring operate.
3) The limitation on mass and volume of the spring.
4) The expected fatigue life.
5) Environmental condition in which spring operate (temperature, corrosive
atmosphere).

4.1 Design Analysis Chapter-Four

4.2.1 Design of Single Disc Plate Clutch
Figure 7: Single Disc Plate Clutch
4.2.2 Considerations in Designing a Friction Clutch

The following considerations must be kept in mind while designing a friction clutch.
⭢ The suitable material forming the contact surfaces should be selected.

⭢ The moving parts of the clutch should have low weight in order to minimize the inertia
load, especially in high speed service.
⭢ The clutch should not require any external force to maintain contact of the friction
surfaces.
⭢ The provision for taking up wear of the contact surfaces must be provided.
⭢ The clutch should have provision for facilitating repairs.
⭢ The clutch should have provision for carrying away the heat generated at the contact
surfaces.
⭢ The projecting parts of the clutch should be covered by guard.


4.2.3 Design Specification
 The allowable shear stress for the spring wire may be taken as 420 Mpa.
 Number of springs are = 6.
 Vehicle transmit power (p) = 100 Kw at 1500 rpm.
 Maximum pressure (Pressed asbestos on cast iron or steel material) = 0.25 N/mm2
 Coefficient of friction (Pressed asbestos on cast iron or steel material),  = 0.3.
 Number of pairs of friction (or contact) surfaces, n = 2
4.2.4 Design of the shaft

Let d = Diameter of shaft
We know that the torque transmitted,
P  60
T 100103  60  636.6 N  m
2π   2π 1500
N
T  636.6103 N - mm
We also know that the torque transmitted (T),
T π 
τ shaft d3
16
π
636.6  103 N  mm   d3
16 N
62.5 mm 2
d  52.7 say 55 mm
mm
4.2.5 Design Mean radius and face width of the friction lining
Figure 8: Forces on a disc clutch
Consider two friction surfaces maintained in contact by an axial thrust, W as shown in fig 0.2

Let r1 = Outer radius of the friction plate, and
r2 = Inner radius of the friction plate.
T = Torque transmitted by the clutch,

p = Intensity of axial pressure with which the contact surfaces are held
r = Mean radius of the friction face, and
μ = Coefficient of friction.
R = Mean radius of the friction lining, and

R
b = Face width of the friction lining =
4
The uniform pressure theory gives a higher friction torque the uniform wear theory.
Therefore in case of friction clutches, uniform wear should be considered, unless
otherwise stated.
The area of the friction faces,
A  2  R  b
Normal or the axial force acting on the friction faces,
W  A  p  2  R  b  p
🡆 Torque transmitted torque by clutch (Frictional torque acting on the friction surfaces),
T  μ W  R  n  μ  (2π  R  b  p)R  n
R
T  μ  (2π  R   p)R  n
4
π
T  μR pn3
2
π
636.6  103 N  mm   0.3  R 3  0.25N 2
2 mm2
2  636.6  103
R3 mm3
0.3  0.25  2
R  204 R 204 mm
mm and b    51 mm
4 4

4.2.6 Design Outer and inner radii of the clutch plate
🡆 We know that for uniform wear, mean radius of the clutch plate,
r1  r2
R 2   r  2R  2  204 mm
r1 2
r1  r2  408 mm.
🡆 Since the face width (or radial width) of the plate is equal to the difference of the
outer and inner radii, therefore,
b  r1  r2
51mm  r1  r2 and the above equation r1  r2  408 mm.
use simultaneous to obtain r1 and r
2
r1  r2  408

mm
r1  r2  51mm
r1  229.5 and r2  178.5 mm
Then we will obtain mm
🡆 And mean radius of the contact surface for uniform pressure conditions,
R  2  r1   r2    2  229.5  178.5
 3 3
  3 3

3  r 2  r 2  3  229.52  178.52 
1 2
R  205 mm
4.2.7 Design for Maximum, minimum and average intensity of pressure.

 For considering uniform pressure:
When uniformly distributed pressure is applied over the entire area of friction face,
p
 W
 [ r1   r2 
2 2 
Normal or the axial force acting on the friction faces,
W  A  p  2  R  b  p
W  2  204 mm  51 mm  0.25 N 2
mm
W  16342.5 N

Axial force is required to engage the clutch,
W  2  Cr1  r2 and C  p  C  constant
 r,
The maximum intensity pressure occurs at inner radius (r2) of friction surface,
C  pmax  r2
Total force acing on the friction surface, W  2  Cr1  r2 
W
C   16342.5 N 
2 r1  r2 2 229.5 mm 178.5 mm
C  51 N
mm
C 51 N mm
pmax  
r 178.5 mm
2
pmax  0.285 N
2
mm
The minimum intensity pressure occurs at outer radius (r1 ) of friction surface,
C 51 N mm
pmin  
r1 229.5 mm
pmin
 0.222 N
mm 2
The average pressure on the friction surface
Total force on friction surface
Pavg 
Cross- sectionalareaof friction surface
W 16342.5 N

Pa 

[ r1  
2
2
 [ 229.5mm 2
 
Pavg  0.25 N 2
mm


4.2.8 Design for the spring
Let D = Mean diameter of the spring, and

d = Diameter of the spring wire.
n = Number of active coils,
G = Modulus of rigidity for the spring material = 84kN 2 ,
mm
W = Axial load on the spring,
τ = Maximum shear stress induced in the wire,
C = spring index = 6
p = Pitch of the coils, and
δ = Deflection of the spring, as a result of an axial load W.
⮣ The axial force on the friction faces,
W = 2π R.b.p = 2π × 204 mm × 51 mm × 0.25 N/mm2 = 16342.5 N
In order to allow for adjustment and for maximum engine torque, the spring is designed for an
overload of 25%.
∴ Total load on the springs = 1.25 W = 1.25 × 16342.5 N = 20428.125 N
Since there are 6 springs, therefore maximum load on each spring becomes, C = 6
Ws = 20428.125N
 3404.8 N
6
⮣ We know that Wahl's stress factor,
4C 1 (4  6) 1 0.615
K 0.615
4C  4
 C   6
(4  6)  4
K  1.2525

⮣ We also know that maximum shear stress induced in the wire (τ),
8 Ws  C
  K d2
420 N 8  3404.8 N 
6
mm2  1.2525
d2
d  204696.57 Nmm 2
420   N  12.45 mm
From the standard table we shall take a standard wire of size SWG 7/0 having diameter
(d) = 12.70 mm.
∴ Mean diameter of the spring coil, D = C×d = 6×12.70 mm = 76.2 mm
Let us assume that the spring has 6 active turns (i.e. n = 6).
⮣ Compression of the spring,
8 W  C 3  n
8  3404.8 N  6  6
3
 
 s
Gd
84000N mm 2 12.70 mm
  33 mm
Assuming squared and ground ends, total number of turns, n' = n + 2 = 6 + 2 = 8.
⮣ Free length of the spring, LF = (n'×d) + δ + 0.15 δ
= (8×12.70 mm) + 33mm + (0.15 ×33 mm)

= 139.55 mm
⮣ And pitch of the coils LF 139.55 mm

= n'1  8 1  20 mm


4.2 Detail Drawing
4.2.1 Component
Figure 9: Plate

Figure 10: Spring

Figure 11: Friction surface
4.2.2 Assembly

Figure 12: Assembly


Chapter-Five
5.1 Result and Discussion
5.1.1 Results
Table 1: Result for all component of single plate clutch disc
S.No Component Result
1 Shaft Diameter of shaft (d) 55 mm

Mean radius of the friction lining, R 204 mm
Face width of the friction lining, b 51 mm
Outer radius of the friction plate, r1 229.5 mm
Inner radius of the friction plate, r2 178.5 mm
The maximum intensity pressure 0.285 N
2 Friction plate occurs at inner radius (r2) of friction mm
2
surface,
pmax
The maximum intensity pressure 0.222 N 2
occurs at inner radius (r1) of friction mm
surface,
pmin
The average pressure on the friction 0.25 N 2
surface, Pavg mm
Mean diameter of the spring, D 76.2 mm
Diameter of the spring wire, d 12.70 mm
Deflection of the spring, as a result of 33 mm
3 Spring an axial load, δ
Free length of the spring, LF 139.55 mm
Pitch of the coils, p 20 mm

5.1.2 Discussion
The main objective of this project is to design preferable single plate clutch disc. As mentioned
above analysis and result show that the design is effective with the help of selected material for
the friction plate and spring, the all result dimension helps to assemble or to draw the model.
Since, the maximum intensity pressure greater than the permissible intensity pressure, minimum
pressure less than the permissible intensity pressure and average intensity pressure equal to the
permissible intensity pressure occurs in the friction surface. Therefore, the design is safe and
effective.

Chapter-six
6.1 Conclusion
This paper explains the design of single plate clutch disc, the parts or component is designed by
using theoretical calculations. The theoretical calculations shows that the material selected for
the friction surface and spring is best. On the other hand the design is preferable or effective,
since the intensity pressure is appropriate with respect to permissible intensity pressure. The
detail drawing (Assembly and component) is drawn by using SOLIDWORK 2016 software.

Reference
1. A Textbook of Machine Design by R.S.KHURMI AND J.K.GUPTA.
2. Shigley`s Mechanical Engineering Design, Eighth Edition.
Internet referred
1. Clutch Design,http://www.thecartech/com/subject/de sign/Automobileclutchs.htm.
2. Automobile clutch, http://www.tep.engr.tu.ac.th.
3. Different international journal, www.semargroup.org
4. Google.com
5. Wikipedia.com
6. scribd.com

Appendix
Table 2: Properties of materials commonly used for lining of friction surfaces.
Table 3: Standard wire gauge (SWG) number and corresponding diameter of spring wire.

Design Single Plate Clutch Disc

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Design Single Plate Clutch Disc

System Analysis and Design (Dire Dawa University)

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PREPARED BY: SELEMUN WELDEDAWIT R/1362/06 I

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In design of the friction clutches of automobiles, knowledge on the thermo-elasticity a priori is

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1.2 Function of clutch

1.3 Working Principle of Single Plate Clutch Disc

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Figure 1: Main Part of Clutch System

1.4 Characteristics of a good clutch

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1. Disc or plate clutches (single disc or multiple disc clutch),

1.6 Component of clutch

Figure 2: Clutch components

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Three common uses of a flywheel include

 They provide continues energy when the energy source is discontinues.

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Figure 4: friction or disc clutch

D. Pressure Plate assembly: Pressure plate assembly with coil

spring: The main parts of a pressure plate assembly are:

 Pressure plate cover

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Figure 5: Assemble of internal parts of clutch

E. Pressure plate assembly with Diaphragm type spring:

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Figure 6: Clutch with diaphragm spring

1.7.2 Specific objective

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In project various methods is used to collect data and information.

Different softcopy books.

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2.1 Literature Review Chapter-Two

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1. It should have a high and uniform coefficient of friction.

⭢ Absorb shocks and vibrations

1) Load acting on the spring.

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