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 Coefficient of Maximum Maximum

Material Friction Pressure Temprerature
Against Steel
or Cl kpa oC

Sintered metal 0.15-0.45 1030-2070 232-677

 LITERATURE REVIEW
s.no Project title & author
1 Design and finite element
analysis of an automotive
clutch assembly
Rajesh Purohit, Pooja
Khitoliya and Dinesh Kumar
Koli.
Description
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
2 Design and analysis of clutch
using sintered iron as a friction
material
Mamta G. Pawar, Monarch K.
Warambhe and Gautam R. Jodh
description
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 In this project, a 3D model of multi-
mutiplate clutch using different plate clutch and its assembly has been
friction material done using Pro-E software packages.
Anil Jadhav, Gauri Salvi, Structural analysis on clutch plate has
Santosh Ukamnal and been carried out using ANSYS
Prof.P.Baskar 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 In this paper, to investigate how a
composite material crack propagates and grows in a clutch.
K.Praveen, rakesh jalla 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 In this project, the feasibility of

of a Clutch Facing Material: applying a simple and cost effective
Effects of Temperature and sliding friction testing apparatus to
Pressure study the friction behavior of a
clutch facing material, effected by the
variation of temperature and
contact pressure, was investigated. 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.
S.N Project title & author
o
6 Optimizing friction behavior of
clutch facings using pin-on-disk
test
Khamlichi A, Bezzazi M.
Description
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 & Description
author
7 Analysis of density In engineering application is largely dependent on the
of sintered iron development of higher density materials and
powder component improved mechanical properties. An experimental
using the response investigation have been undertaken in order to
surface method understand the variation of density with respect to the
Prasanta kumar variation of process parameters such as compaction
bardhan, suprs load, sinter temperature and sintering time.
patra and goutam In this project, a detail microstructure analysis has
sutradhar 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.N Project title & author Description
o
8 THE EFFECT OF BORON LIQUID PHASE
In this project, they concluded that Boron is
SINTERING ON PROPERTIES OF ni-,
evaluated as the best sintering enhancing element
mo-, cr- ALLOYED STURUCTURALin terms of identifying the iron-based materials
STEELS by formation the liquid phase. The influence of
M. Selecka, A. Salak and H. boron addition (up to 0.6%) on the density,
Danninger 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.N Project title & author Description
o
9 Hoganas “(SINTERED IRON BASED Hoganas has developed a variety of
MATERIALS)” 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.N Project title & author
o
10 Experimental
characterization of frictional
behaviour of clutch facings
using Pin-on-disk machine
M.Bezzazi, A. Khamlichi
Description
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 DEFINITION

PROBLEM CHARACTERISTICS CAUSES

Distortion Facings out of flatness after Unsuitable friction material

high operating temperature

Reduced performance Decrease in coefficient of Excess oil or grease on

friction giving a friction material or on the
permanent loss in opposing surface
performance

Burstfailure Material splitting and High stresses on facings

removed from the spinner when working at high
plate Speeds

Crushing Loss of friction material at Crushing and excessive

the ends of a band wear Of the friction material
• 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
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ISSN: 2320 – 8791 Volume 1, Issue 4, Aug-Sept, 2013.

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“ANALYSIS OF DENSITY OF SINTERED IRON POWDER
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METHOD” Materials Sciences and Applications, 2010, 1,
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• M. Selecka, A. Salak, H. Danninger, “THE EFFECT OF

BORON LIQUID PHASE SINTERING ON PROPERTIES
OF Ni-, Mo-, Cr- ALLOYED STURUCTURAL STEELS”
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• Hoganas , “SINTERED IRON BASED MATERIALS”
http://riad.pk.edu.pl/~mnykiel/iim/KTM/MP/DOWNLOAD/pd
f/CHAPT09.PDF

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

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http://thomasbct.com.au/wp-
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Transmission”
• A. Chaikittiratana, S. Koetniyom, S. Lakkam ”Static/kinetic
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Temperature and Pressure”

• A. Khamlichi, M. Bezzazi, A. Jabbouri, P. Reis and J. P.

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THANK YOU