CAREER EPISODE 1

3.1 Introduction
 Project Title: Analysis on a clutch plate using different materials
 Chronology: Insert date
 Institution: Gujarat Technological University
 Name of the institute: Saraswati Institute of Engineering and Management
 Location: Rajpur, India
 Supervised by: Insert Supervisor
 Project Position: Team Head
1.2 Background

1.2.1

The primary function of a clutch is to initiate movement or increase the speed of a vehicle by
exchanging kinetic energy with some other moving body. Clutches come into use when there are
two pivoted (spinning) shafts in a machine. Usually, a motor, pulley, or engine determines one
shaft, while the other shaft powers another piece of equipment. It helps in engaging or
disengaging the engine's main output power shaft with the vehicle's driving shaft. Various
varieties of the clutch are used according to the inputs, speeds, material, and torque supplied and
the overall use of the mechanical system. The frictional force between different plates of the
clutch connects the two independent shafts and allows the smooth power transmission as the
single one. The clutch is a system in and of itself, utilizing various layouts and standards in
various models available. The stresses developed on the clutch plates are very crucial for the
designer which must be overcome by the material during the power transmission.

This project focused on the design of a clutch plate and the analysis of the stress on the clutch
plates. The selection of different competitive materials such as SF001-AL6061 alloy, AL6061
steel, SF001 steel, and steel, was made for the investigation of the stress. The calculation of
various clutch design specifications, including uniform pressure and uniform axial wear, was
done considering the clutch plate's power, torque, and dimensions. The modeling of the clutch
base plate and other clutch assembly components was done using SolidWorks software. Finally,
the analyses of the stress were performed for different materials in the ANSYS.
1.2.2 Aims

The main objective of this project was to design the clutch plate and evaluate the stress on
different materials. Additional aims were:

 To make the best selection of the material for clutch plate by analyzing their structural
performance.
 To model the clutch plate with strong wear resistance and high reliability.

1.2.3 Organization Chart

Gujarat
Technological
University

Saraswati
Institute of
Engineering &
Management

Department of
Mechanical
Engineering

Mentor name

Trishulkumar
Natvarbhai Patel Team members
(Team Leader)

Figure 1 Organizational Chart

1.2.4 Duties
  To gain a deeper understanding of the design of clutch and its stress analysis from
different literature papers.
 To explore and select different materials for the design of the clutch plate.
 To perform the theoretical design and determination of various clutch plate parameters.
 To construct the CAD model of the proposed clutch plate.
 To perform the stress analysis on the friction clutch plate using ANSYS.

1.3 PEA

1.3.1

I began this research project by doing an in-depth review of various literature papers related to
the design of the friction clutch plate. I gathered different journals, research project papers,
material data books, machine design books, and other online articles. I did a thorough review of
the design methodology of the frictional clutch plate. I learned the basic working mechanics of
the clutch plate which would allow the engagement and disengagement of the engine driving
shaft. I acknowledged the clutch plate as the power transmitting agent which would connect the
output shaft from the main engine to the driven shaft. I also reviewed the mechanical, hydraulic,
electrical type operating clutch plate. I studied the design techniques considering the engine
power, torque and learned the modeling of the friction plates using the theoretical calculation
means. I gained the skill to develop the CAD model and the assembly design of the clutch and
also studied the stress analysis techniques using the computational method.

1.3.2

I began the selection of different materials for the design of the clutch plate. I explored the
numerous competitive materials by visiting different sites, workshops, and the metal industries. I
gave the priority of high mechanical strength, including the wear-resistant material, high stress-
bearing capacity, and easy machining or manufacturing method. Finally, I chose four different
materials, namely SF001-AL6061 alloy, AL6061 steel, SF001 steel, and steel, which were most
prevalent in designing the friction clutch plate for the vehicle. I chose theme materials due to
their high yield strength and good mechanical properties. Furthermore, I chose the CAD software
SolidWorks to construct the 3D model of the clutch base plate and the assembly model.
Likewise, I selected ANSYS software to conduct the stress analysis on the proposed model of the
clutch plate.

1.3.3

I moved into the design and the calculation phase of the project after the literature review and the
material selection. I began the calculation by considering different specifications such as power,
torque, maximum pressure, and temperature. I accounted inner and outer diameter of the friction
face and considered an appropriate number of the disc on the driving and the driven shaft and
then determined the mean radius of the friction surface of the clutch plate. I considered the
uniformly distributed pressure over the surface of the frictional region and determined the
intensity of the pressure. I calculated the torque taking the axial thrust to hold the surfaces
together, and then determined the pressure. I computed the torque transmitted by considering the
uniform axial wear on the clutch plate. I determined the maximum and the minimum pressure at
the inner and the outer radius of the clutch plate and then determined the average pressure acting
on the frictional surface.

Calculations:

Specs of the car engine

Power = 12 BHP in 7800 rpm

Torque = 12,000 N-mm

Friction coefficient (µ) = 0.30

Highest pressure that can be applied on the clutch plate (P) = 0.35 N/mm2

Let r1 and r2 be the outer and inner radius of the clutch plate, and their values are 108 mm and 88
mm, respectively.

Let n1 and n2 be the disc number, and their values are 5 and 8 mm, respectively.

So, number of contacting pairs (n) = n1 + n2 = 8

From uniform wear, mean radius (R) = (r ¿ ¿ 1+r 2 )/2¿ = (108 + 88) / 2 = 98 mm
 2 ( r 1−r 2 )
3 3

From uniform pressure, mean radius (R) = =98.34 mm

3 r 21−r 22

Uniform pressure theory

W
P= 2 2
, where W =axial load ¿ hold the plates
π (r 1−r 2)

Frictional torque (T) = μ ×W × n× R=0.3 × W × 8 ×98.34

12000 = 0.3 ×W × 8 ×98.34

So, W = 50.84 N

50.84
So, P = 2 2
=0.00413 N/mm2
π (108 −88 )

Uniform wear theory

W
P= 2 2
π (r 1−r 2)

Frictional torque (T) = μ ×W × R=0.3 ×W × 98.34

12000 = 0.3 ×W × 98.34

So, W = 406.75 N

406.75
So, P = 2 2
=0.033 N/mm2
π (108 −88 )

Uniform axial wear

P x r = C, (C = constant)

R = (r ¿ ¿ 1+r 2 )/2¿ = (108 + 88) / 2 = 98 mm

Axial force (W) = 2πC (r1-r2)

Frictional torque (T) = μ ×W × n× R=0.3 × W × 8 ×98.34

12000 = 0.3 ×W × 8 ×98

So, W = 51.02 N

Maximum pressure is at the inner radius so,

r2 x Pmax = C

W 51.02
Also, C = = =0.406
2 π (r 1 +r 2) 2× π ×(20)

Now, Pmax = C / 88 = 0.004613 N/mm2

Pmin = C / 108 = 0.00376 N/mm2

W 2
Pavg = 2 2
=0.00414 N /mm
π (r 1 −r 2)

1.3.4

I began the preparation of the CAD modeling for the designed friction plate using the
SolidWorks software. At first, I sketched the 2D model of the base plate by drawing the two
concentric circles with calculated diameters. I extruded these circles using the extrude boss
feature and obtained the stepped circular base plate of the proposed clutch. I used extrude cut
feature and made a hole on the base plate, and then used the circular pattern to make another hole
around the base plate. Likewise, I sketched the 2D model of plate 1 and plate 2 and then used the
extrude feature to obtain the solid structure of the clutch plates. Finally, I assembled the plates
with the base plate in the assembly window. I used the concentric mate to adjust the plates with
the base plate of the clutch and also used the coincident mating to configure the plate models and
finally obtained the assembled model of the friction clutch.

Insert design

1.3.5

I uploaded the model of the clutch plate into the ANSYS Workbench and then began the
analysis. I began the material definition and then produced the meshed structure. I used the
tetrahedral mesh with a minor element size to obtain the finer mesh with good quality. Likewise,
I applied the boundary conditions like pressure load and the fixed support and then began the
simulation in the ANSYS. I generated the solution and then opened it in the post-processing
window. I generated the stress and the displacement contour on the plate model and analyzed its
distribution. I followed similar analysis steps for all the material. I analyzed the strength of all
the clutch plates and found that the stress on the clutch plate made up of material cork and SF001
was low. I also found the displacement under the acceptable range. I observed low density with
low weight for the plate made up of Aluminum 6061. Finally, after analyzing all the results of
the simulation, I concluded that the AL6061 material would be the better choice which could
withstand high stress and also facilitates low weight design than other steel materials.

Insert analysis results

1.4 Technical Problems and Solutions

1.4.1

While observing the deformation plot on the clutch plate structure, I observed an extremely high
magnitude of deformation on the clutch plate's outermost parts. I realized the design to be unsafe
and could not transmit the desired power and torque. So, I reviewed more literature and
discussed with my project supervisor to look for possible solutions. I came to know that the low
thickness of the clutch plate resulted in this issue. I also knew that the friction surface was too
small to withstand high pressure during the contact. So, I increased the thickness of the clutch
plate. Finally, I analyzed this new model of the clutch plate and found that the deformations over
the surface of the plate were lower than the previous design. Therefore, I eliminated this problem
of high deformation and made the design safe for the desired power transmission.

1.4.2

I found high stress concentrated on the different regions of the clutch plate, which indicated plate
failure during the power transmission. I inspected the model of the clutch plate and observed too
many sharp edges and the pointed regions, which acts as the stress accumulation regions. So, I
researched the techniques to eliminate such critical regions. I used the tools like fillet and the
chamfer with appropriate radius and applied them to those regions. I made the smooth finish and
eliminated the sharp edges on the clutch plate. Now, on simulating this structure, I found high
stress was not accumulated on those regions as the sharp edges were removed. So, finally, the
design of the clutch plate was made ready for operation.
1.5 Creative Works

I increased the frictional surface to make the clutch structure stronger for the high pressure
during the contact. I used the fillet and chamfer tool to remove the sharp edges and eliminate the
clutch plate's high-stress concentration.

1.6 Team Management and Codes

My team member nominated me for the project group leader position. So, I handled a variety of
duties which included allocating and assigning work within the group. I divided the task based
on the interest and knowledge levels of my colleagues. Similarly, I gathered the relevant journal
papers and articles and shared them with my group. Likewise, I arranged weekly meetings
with my project supervisor to ask any questions concerning the project. In addition, I monitored
the status of my project to make sure that every task was finished on time. Finally, I strived to
inspire and support my teammates if they were confused about something.

To understand the technical features and terminologies of the vehicle clutch plate, I utilized ICS
21.120.10. Furthermore, to grasp the standards of clutch plate facings, I reviewed the IS:
3649 (1996).

1.7 Summary

This study achieved to complete the design and assessment of an automobile clutch plate. To

evaluate and compare the structural strength of the materials, SF001-AL6061 alloy, AL6061
steel, SF001 steel, and steel, were chosen as the clutch plate's material. The radius of the clutch
plate was computed by using uniform pressure and uniform wear theory, and the average
pressure on the clutch plate was determined. The model was assessed in ANSYS for all the
materials, and it was found that AL6061 material resisted the stress and deformation more
effectively than others. All the material could be used in the clutch plate as the stresses were
under the allowable material stress.

This project allowed me to develop and polish my leadership qualities.  I was also able to

strengthen my communication skills. I maintained strong bonds with my team and learned how
to work effectively in a group.