Work term presentation

LuK-Schaeffler

Introduction

Hamaish Khan 3rd year Mechanical Engineering with Automotive honors

student

Extended work term (12-months) in Durability department at LuK-Schaeffler,

Buehl, Germany

Company overview:
LuK is a member of the Schaeffler Group along side with INA and FAG, which is
internationally renowned automotive manufacturer for clutch, transmission
components, torque converters and torsion dampers etc

Job responsibilities
Making finite element models, performing analysis, reporting and presentation
Performing static, temperature, heat transfer and modal analysis
Strength assessment
Performing highly non-linear simulations
Supporting in new method development of thermo-shock and thermomechanical test for clutches
Simulating diaphragm spring characteristics
Parametric study on the influence of material properties on deflections in
clutches
Validations of FEA models
Working with externals CADFEM GmbH for programming models

Agenda

Introduction to work term report topic

Current Project status
Further requirements for the project

Project - Topic

The problem was to model the outcome from thermo-shock test for clutches
in the ANSYS Workbench (FEA software). Precisely, to get the same results
(e.g. deflections, cracks etc.) as seen in thermo-shock test

Automotive clutch

FEA model

Overview of test

Thermo-shock test
The goal of the test is to verify the pressure plate/flywheel strength durability
mounted in the clutch plate during an energy overload of 15 sec.

Working of mechanical clutch

Thermo-shock test results

Results from the actual test rig

Overview of FEA model

Simplified clutch disk would be
axially fixed

A pressure dependent heat

flux is introduced into the
contact using UPFs (User
programmable features).

Simplified clutch disk

Pressure plate

Axial force is applied on the load clamp

areas of pressure plate

Pressure plate geometry CAD

Results from FEA

Contact pressure (LC 1)

Contact pressure (LC 6)

Local High
pressure

MPa

MPa

Temperature distribution (LC 1)

Avg. difference : 230 C

Temperature distribution (LC 6)

Avg. difference : 1537C

Results from FEA

Heating up time (LC 1)

Heating up time (LC 6)

Significant increase
in axial delfection

Furture concern

Integration of wear model

With wear

Without wear
1 sec

10 sec

15 sec

Pressure distribution

Conclusion

Experienced gained

Finite element modelling

knowledge of User programmable features UPFs (ANSYS)
High performance computing (HPC)
Working of mechanical clutches
Knowledge of thermo-shock and thermo-mechanical test for clutches

Thank you for your attendance