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Design 4teme
Design 4teme
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.
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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.
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.
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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
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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
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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.
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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.
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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.
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Though there are many types of friction clutches, yet the following are important from the subject
point of view:
Fly wheel
Friction/clutch disc
Pressure plate assembly and
Release/control mechanism
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.
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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
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.
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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.
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.
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The face of the pressure plate is a large, flat ring that contacts the clutch disc during clutch
engagement.
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.
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.
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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.
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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.
Then after designing the parts by theoretical calculation, the design is modeled by using the
SOLIDWORK 2016 software.
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Chapter-Two
2.1 Literature Review
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.
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Chapter-Three
3.1 Material Selection
The material used for lining of friction surfaces of a clutch should have the following
characteristics:
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:
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Chapter-Four
4.1 Design Analysis
4.2.1 Design of Single Disc Plate Clutch
⭢ 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.
T π τ shaft d 3
16
π
636.6 103 N mm 62.5 N d3
16 mm 2
d 52.7 mm say 55 mm
4.2.5 Design Mean radius and face width of the friction lining
Consider two friction surfaces maintained in contact by an axial thrust, W as shown in fig 0.2
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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 R3 p n
2
π
636.6 103 N mm 0.3 R 3 0.25 N 2
2 mm2
2 636.6 103
R 3 mm3
0.3 0.25 2
R 204 mm
R 204 mm and b 51 mm
4 4
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🡆 And mean radius of the contact surface for uniform pressure conditions,
R 2 r1 r2 2 229.5 178.5
3 3
3 3
When uniformly distributed pressure is applied over the entire area of friction face,
p
W
[ r
1
2
r
2
2
W A p 2 R b p
W 2 204 mm 51 mm 0.25 N 2
mm
W 16342.5 N
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The maximum intensity pressure occurs at inner radius (r2) of friction surface,
C pmax r2
C
51 N mm
pmax
r2 178.5 mm
pmax 0.285 N 2
mm
The minimum intensity pressure occurs at outer radius (r1 ) of friction surface,
C
51 N
pmin
mm
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
Pavg W
[ r r [
2
16342.5 N
229.5mm 178.5mm 2 2
1 2 2
Pavg 0.25 N 2
mm
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In order to allow for adjustment and for maximum engine torque, the spring is designed for an
overload of 25%.
Since there are 6 springs, therefore maximum load on each spring becomes, C = 6
20428.125N
Ws = 3404.8 N
6
4C 1 (4 6) 1 0.615
K 0.615
4C 4 C (4 6) 4 6
K 1.2525
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⮣ We also know that maximum shear stress induced in the wire (τ),
8 Ws C
K
d2
8 3404.8 N 6
420 N 2 1.2525
mm d2
204696.57 Nmm 2
d 12.45 mm
420 N
From the standard table we shall take a standard wire of size SWG 7/0 having diameter
(d) = 12.70 mm.
Let us assume that the spring has 6 active turns (i.e. n = 6).
⮣ Compression of the spring,
8 W s C 3 n 8 3404.8 N 6 3 6
Gd 84000N 12.70 mm
mm 2
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
LF 139.55 mm
⮣ And pitch of the coils = 20 mm
n'1 8 1
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Detail Drawing
4.2.1 Component
Figue 9: Plate
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4.2.2 Assembly
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Chapter-Five
5.1 Result and Discussion
5.1.1 Results
Table 1: Result for all component of single plate clutch disc
pmax
The maximum intensity pressure occurs 0.222 N 2
at inner radius (r1) of friction surface, mm
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
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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.
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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.
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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
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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.
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