Chapter 4 - Transmissions and Driveline - Clutch

MODERN AUTOMOTIVE DESIGN
Le Van Nghia, PhD

Faculty of Transportation Engineering
Chapter 4: Transmissions and driveline
• Introduction
• Demonstrate the need for transmission design and
matching.
• Give examples of common clutch, gearboxes and

transmissions available for vehicle design.
• Indicate the terminology and methods for transmission

design.
• Aid the designer to understand the elements of the

analysis of transmission systems.
3
What the vehicle requires from the transmission
✓ Allowing the vehicle to start from rest, with the engine running continuously.
✓ Letting the vehicle stop by disconnecting the drive when appropriate.
✓ Enabling the vehicle to start at varied rates, under a controlled manner.
✓ Varying the speed ratio between the engine and wheels.
✓ Allowing this ratio to change when required.
✓ Transmitting the drive torque to the required wheels.
4
Transmission’s components
5
Clutch
1. Clutch overview
2. Structure of clutches
3. Clutch design
- Determination of needed torque
- Design of clutch mechanism
- Design of clutch driver
6
Clutch
1. Clutch overview
- Clutch position: between engine and gearbox
- Clutch functions:
1. The clutch helps the engine to run at a stationary position.
2. It can be used to reduce engine speed.
3. It enables easy changing of gears.
4. Smooth vehicle control is achieved.
5. It’s a safety element for transmission.
7
Clutch
1. Clutch overview
- Clutch position
- Clutch functions
- Clutch classifications:
• Manual clutches (dry friction clutch).
• Hydraulic clutches (hydraulic torque converter).
• Electric clutches (air compressor, differential).
• Centrifugal clutches (motorbike).
8
Clutch
1. Clutch overview
- Clutch position
- Clutch functions
- Clutch classifications:
• Dry clutch classification
• Single-Plate Clutch – Advantages and Disadvantages?
• Double-Plate Clutch – Advantages and Disadvantages?
• Dry clutch with diagram spring, coil spring, conical spring
• Automatic or semi-automatic Dry clutch, manual clutch
9
Clutch
1. Clutch overview
Clutch disks
Advantages and Disadvantages ?
10
Clutch
1. Clutch overview
Clutch springs
Solo Adjustment-Free Heavy Duty Clutch
11
Clutch
1. Clutch overview
Automated clutches
pneumatic actuator
Electric actuator
12
Clutch
1. Clutch overview
clutch-by-wire with electronic hydraulic actuator
13
Clutch
2. Structure of clutch system
Working scheme of Clutch system

1-Flywheel; 2-Friction disk; 3-Pressure plate; 4-Pressure spring; 5-Clutch cover; 6-Realease
bushing; 7-Clutch pedal; 8-return spring; 9-pull lever; 10-open lever; 11-Realease bearing;12-
open bar; 13-damper; 14-Intermediate plate; 15-return spring.
14
Clutch
Clutch structure
1-Flywheel; 2-Friction disk; 3-Pressure plate;
4-Pressure spring; 5-Clutch cover; 6-Realease
bushing; 7-Clutch pedal; 8-return spring; 9-
pull lever; 10-open lever; 11-Realease
bearing;12-open bar; 13-damper; 14-
Intermediate plate; 15-return spring.
15
Clutch
Clutch manipulating mechanism

1.dual mass flywheel, 2.clutch cover, 3.mechanical releaser, 4.pedal vibration damping device, 5.clutch
master cylinder (CMC), 6.plastic clutch pedal, 7.clutch slave cylinder (CSC), 8.clutch (friction) disc
16
Clutch
Pressure spring
a) Diaphragm spring b) coil spring c) conical spring
17
Clutch
Pressure spring characteristics
Diaphragm spring coil spring conical spring
18
Clutch
Clutch friction disc
19
Clutch
3. Clutch design
- General requirements of clutch
• –Transmit Full Engine Torque without slipping;
• –Definitively disengage and softly engage for reduction dynamic load on
transmission;
• –The inertia moment of the passive part should be as small as possible in
order to reduce the dynamic load on the gears and the synchronizer during
gear shifting;
• –Frictional torque remains constant when clutch is engaged;
• –Avoid resonance in transmission with high frequency of combustion
engine;
• –Good heat dissipation to avoid heating the parts while clutch slipping;
• –Long life, compact size, easy to use, maintain and repair, low cost.
20
Clutch
3. Clutch design
- General requirements of clutch design
• ✓ Ensure good performance of functions and tasks;
• ✓ Minimum size and volume;
• ✓ Durable, long life, low cost;
• ✓ High reliability, convenient in use, maintenance and repair, low cost;
✓Defining basic parameters
→ Setting up the sketch
drawing;
✓Check working conditions,
operability;
✓Calculation of details
(dimensions, materials,
Base clutch technical requirements,
Designed clutch durability assessment, ...);
21
Clutch
3. Clutch design
- 3.1 Clutch Necessary Friction Torque
Memax – engine max. torque
ᵦ- reserve coefficient - Passenger car, commercial car

-Truck, bus
- Vehicle with high maneuverability
- Semi-truck, trailer
Designed clutch
22
Clutch
3. Clutch design
- 3.2 Clutch mechanism design
✓ Number of friction discs;
✓ The dimensions of the friction disc;
✓ Required pressure force;
✓ Number of springs, force of a spring;
✓ Dampers (springs, friction plates).

23
Clutch
3. Clutch design
Friction Torque
Mc – friction torque
η – friction coefficient 0.25-0.35
FN – pressure force
Rη – friction radius
zη – number of friction disc
24
Clutch
3. Clutch design
Friction disc diameters
– small passenger car

– truck, bus
– vehicle with hard working condition
– if ne – fast engine (petrol engine), choose r smaller

– if ne – low engine (diesel engine), choose r bigger
25
Clutch
3. Clutch design
Friction pressure force
check pressure on the friction surfaces:
26
Clutch
3. Clutch design
Slipping energy Specify Slipping energy
Engage process Engage process modelling

Calculation of Engage process
27
Clutch
3. Clutch design
Slipping energy calculation
t1
Assumption 𝑀𝑐 (𝑡) = 𝑘 ∗ 𝑡, 𝑀𝑑 (𝑡) = 𝑘 ∗ 𝑡
𝑀𝑑 = 𝑀𝜓 = 𝑘 ∗ 𝑡1
28
Clutch
3. Clutch design
Assumption:
𝜂𝑡𝑟𝑎𝑛𝑠
𝑀𝑑 = 𝑀𝜓 = 𝜓 ∗ 𝐺 ∗ 𝑟𝑤ℎ ∗ = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡
𝑖𝑡𝑟𝑎𝑛𝑠
𝑀𝑐 = 𝑀𝜓 + 𝑘 ∗ 𝑡
t1 𝜔𝑑 =?
𝑡2 𝜔𝑎 =?
𝑊2 = න (𝑀𝜓 + 𝑘 ∗ 𝑡) ∗ (𝜔𝑑 − 𝜔𝑎 ) 𝑡2 =?
0
29
Clutch
3. Clutch design
𝐼𝑑 ∗ 𝜔𝑑ሶ = 𝑀𝑑 − 𝑀𝑐 = −𝑘 ∗ 𝑡 𝜔𝑑 = 𝜔0 − 0.5 ∗ 𝑘 ∗ 𝑡 2 /𝐼𝑑
𝐼𝑎 ∗ 𝜔𝑎ሶ = 𝑀𝑐 − 𝑀𝜓 = 𝑘 ∗ 𝑡 𝜔𝑎 = 0.5 ∗ 𝑘 ∗ 𝑡 2 /𝐼𝑎
𝜔𝑑 − 𝜔𝑎 = 𝜔0 − 0.5 ∗ 𝑘 ∗ 𝑡 2 /𝐼
𝐴𝑡 𝑡ℎ𝑒 𝑡2 𝑚𝑜𝑚𝑒𝑛𝑡: 𝜔𝑑 = 𝜔𝑎 𝑎𝑛𝑑 𝑡2 = 2 ∗ 𝜔0 ∗ 𝐼/𝑘
30
Clutch
3. Clutch design
31
Clutch
3. Clutch design
- Petrol engine
- Diesel engine
ωM, ωN – engine speed at max. torque and max. power

Vehicle type Ψ Gear number Limited of Specify
Slipping energy J/cm2
MΨ=? Passenger Car 0.1 II 160
Truck 0.1 II 160
32
Clutch
3. Clutch design
Vehicle type Ψ Gear number Limited of Specify Slipping

energy J/cm2
Truck 0.02 I 20
0.16 I 45
0.02 II 40
Passenger Car 0.1 II 50---70
33
Clutch
3. Clutch design
Thermal calculation on engage process
c = 481,5 J/kg.○C - specific heat capacity of steel

md – mass of pressure plate, [kg]
For single vehicle
For trailer
34
Clutch
3. Clutch design
Pressure spring calculation – coil spring
Pressure Force:
Force for disengage:
Choose the number of pressure spring Zlx: Characteristic of coil spring

mm- Singer plate
mm- Double plate
Spring stiffness:
35
Clutch
3. Clutch design
Pressure spring calculation – coil spring
Cut stress:
36
Clutch
3. Clutch design
Diaphragm Spring calculation
FN – force at pressure plate

Fn – disengage force
37
Clutch
3. Clutch design
38
Clutch
3. Clutch design
Recommendation:
Number of diaphragm spring blades: 8-20

h/δ >1.6 – big range of constant force
h/δ >2.8 – maybe spring reversing
39
Clutch Cushion segment
3. Clutch design
Damp spring
Damp Spring calculation
Damp Torque :
Friction plate
Center hub
Torque of damp spring: (splined)
Gearbox Input
shaft
Torque of friction disc:
Splined
40
Clutch Cushion segment
3. Clutch design
Damp spring
Damp Spring calculation
Recommendations:
Friction plate
Center hub
(splined)
Gearbox Input
shaft
M’lx – initial damp spring torque
φg – max. angle between cushion and splined Splined
Damp spring: D/d=4.5-5.5, where D – spring diameter, d- diameter of coil

Diameter of spring assembled place : 80-120 mm,
Length of spring assembled place: 25-27mm
41
Clutch
3. Clutch design
Damp Spring calculation D=
Recommendations:
Damp spring: D/d=4.5-5.5, where D – spring diameter, d- diameter of coil

Diameter of spring assembled place : 80-120 mm,
Length of spring assembled place: 25-27mm
Damp spring parameters:
d= 3-4 mm, D=14-19 mm
Turns Number: i=3-4
Distance between turns: Δ=3-4 mm
42
Clutch
3. Clutch design
Release fork calculation:
Zdm – fork number

Wu – blend moment at calculated section
Steel fork -
Cast iron -
43
Clutch
3. Clutch design
Friction disc calculation:
Calculation of Rivets, which connect
friction pad to cushion segment
Forces on rivets:
Cut and bearing (stamping) stresses

Materials: Al or Cu
d – rivet diameter= 4-6mm
n1 and n2 – rivets numbers
44
Clutch
3. Clutch design
Friction disc calculation:
Calculation of Rivets, which connect

friction disc to spined hub
Calculation Method is the same, but the limited

values of stresses are:
Materials: Steel- Fe
d – rivet diameter= 6-10mm
45
Clutch
3. Clutch design
Splined hub calculation:
Standard?
Material?
Dimensions?
Length L=(1-1.4)*d
46
Clutch
3. Clutch design
Clutch shaft calculation:
Clutch shaft = Gearbox

input shaft
Shaft material = material for gear
47
Clutch
3. Clutch design
48
Clutch
3. Clutch design
Exercise: Design a clutch mechanism for 7-seats car based on Toyota Inova 2019
Main steps of Design process:
Step1: Analysis the nowadays construction of clutch mechanism of popular 7-seats
on the market → conclusion about the main type of and choose the type of clutch
mechanism (dry clutch, west clutch, hydraulic clutch,…)
Step2: Analysis the type and construction of the main parts of clutch → conclusion
about the main part type of clutch mechanism (pressure spring, pressure plate,
friction plates, release bearing,…) → select the right types
Step3: Calculate the main parameters of main elements → check out the element’s
durability and draw the clutch mechanism sketch
Step4: Study on clutch mechanism functions by simulation on computer →
optimization the values of main parameters
Step5: Build the assembled drawing → and details drawings
Step6: Make a proper type of designed clutch mechanism → Test on stand
Step7: Test on vehicle → conclusion about production
49
Clutch
3. Clutch design
Clutch driver calculation:
Mission: Help driver control clutch mechanism
Type: Mechanical, Hydraulic, Hydraulic with vacuum power assistant,
Hydropneumatics, Mechanical with pneumatic power assistant.
Mechanical driver
Hydraulic with vacuum

Hydraulic driver
power assistant
Hydropneumatics
Press_air
50
Clutch
3. Clutch design
Main parameters of clutch driver
- Pedal force Qbd;
- Pedal travel Sbd; Sbd=So+Slv
- Clutch driver ratio.
Standard values:
- Qbd <[Q]
- Sbd < [S]
- Small car: [Q]=150N, and [S]=140-160 mm
- Truck, bus: [Q]=250N without power assistant, [Q]=150N with power assistant
and [S]=180 mm
51
Clutch
3. Clutch design
Mechanical clutch driver
• Δ = 1,5 - 2,0 mm – Single disc
• Δ = 2,0 - 3,0 mm – Double disc
• δ = 2,0 - 4,0 mm
There are two ways to design clutch driver
- M1: Choose Qbd <[Q]
Choose dimensions a,b,c by real structure

Free pedal travel
Working pedal travel
Check the pedal travel
52
Clutch
3. Clutch design
Mechanical clutch driver
• δ = 2,0 - 4,0 mm
There are two ways to design clutch driver
- M2: Choose free pedal travel So
Small car
Truck, bus
If Qbd>[Q]?
53
Clutch
3. Clutch design
Hydraulic clutch driver – same as mechanical one
• δ = 2,0 - 4,0 mm
54
Clutch
pk = (0,7 – 0,8) MPa
3. Clutch design
Hydraulic clutch driver
with pneumatic power assistant
- Choose Sbd and So
- Calculate
- Choose a,b,c and calculate

-
Pressure air
- Divide the pedal force:

- Choose the drive force: --- assistant force:
- Force from cylinder:
55
Clutch
3. Clutch design - Sbd?
- Qbd without power assistant?
Clutch driver calculation: - Area of vacuum cylinder if Δh=0,05MPa?
Hydraulic clutch driver with vacuum power assistant
-
air Vacuum
56
Clutch
3. Clutch design
Notes for diaphragm spring
57
Clutch
3. Clutch design
Notes for diaphragm spring
58
Clutch
3. Clutch design
59
Clutch
3. Clutch design
60
Clutch
3. Clutch design
Exercise: Design a clutch driver for 7-seats car based on Toyota Inova 2019
Main steps of Design process:
Step1: Analysis the nowadays construction of clutch driver of popular 7-seats on the
market → conclusion about the main type of and choose the type of clutch driver
(mechanical, hydraulic, hydraulic with power assistant,…)
Step2: Analysis the type and construction of the main parts of clutch driver →
conclusion about the main part type of clutch driver (power cylinder, pressure, pipe,
vacuum chamber,…) → select the right types
Step3: Calculate the main parameters of main elements → check out the element’s
durability and draw the clutch driver sketch
Step4: Study on clutch driver functions by simulation on computer → optimization
the values of main parameters
Step5: Build the assembled drawing → and details drawings
Step6: Make a proper type of designed clutch driver → Test on stand
Step7: Test on vehicle → conclusion about mass production
61
Stepped Gearbox
1. Gearbox overview
2. Structure of gearbox
3. Gearbox design
- Determination of gear ratios
- Design of gearbox’s components
- Design of gearbox’s shifting mechanism
62
Gearbox
1. Gearbox overview
- Gearbox position: after clutch and before final driver
Active wheel
Final driver
Engine Gearbox
Main final driver

Clutch Auxiliary gearbox Auxiliary gearbox Main final driver
63
Gearbox
1. Gearbox overview
- Gearbox functions:
1. Changing the gear ratios.
2. Break the power from engine to transmission.
3. Reverse motion of vehicle.
- Gearbox Classification:
1. By structure: 2-shafts or 3-shafts gearbox
2. By position between input and output shafts: coaxial and no-coaxial gearbox
3. By control method: manual, semi-manual, automatic
64
Gearbox
1. Gearbox overview
- Gearbox Classification:
1. By structure: 2-shafts or 3-shafts gearbox
65
Gearbox
1. Gearbox overview
- Automatic gearbox:
• AT: Automatic Transmissions;
• CVT: Continuously Variable Transmissions;
• DCT: Dual Clutch Transmissions;
• AMT: Automated Manual Transmissions
66
Gearbox
1. Gearbox overview
- General Gearbox’s requirements:
1. Have the appropriate number of gears and gear ratios to ensure the vehicle's dynamics
and fuel economy.
2. Soft shifting gear without noise .
3. Have an anti-shifting mechanism and an anti-setting mechanism for two gears at the
same time.
4. Have a cutting power position from engine
5. Have a signaling mechanism when reverse gear is engaged
6. Have a point for sharing power if needed
67
Gearbox
1. Gearbox overview
2-shaft Gearbox
68
Gearbox
1. Gearbox overview
3-shaft Gearbox
69
Gearbox
1. Gearbox overview – comparison between 2 and 3-shaft gearbox
- Translate power by 2 couple gear

+ Translate power by 1 couple gear →Low efficiency
→Hight efficiency + First gear ratio can be big as needed
+ First gear ratio is not big + Have a direct gear = 1 gear ratio
Hight efficiency ≈1
Direct Working Low Fuel consumption
gear time ≈
No load on elements 70-80 % Hight longevity
70
Gearbox
1. Gearbox overview – Gear ratios
i1 i1
Tractive force
Tractive force
i2
i2
Ideal tractive force Ideal tractive force
i3
i3 i4
i4
i5 i5
speed speed
Progressive Geometric progress
71
Gearbox
72
Gearbox
1. Influence of gear ratio to fuel consumption
Driver →gas pedal → Vehicle speed: V
Vehicle power: P=V*Fc
Road → resistant → Fc
2. Wheel speed
3. Engine speed
For speed V → choose iT → ne with minimum ge
73
Gearbox
74
Gearbox
2. Structure of Gearbox
- Gearbox main components: Gear couples, synchronizers,
shafts, bearings, shifting mechanism, lubrication system,
75
Gearbox
3. Gearbox design
✓Gear couple
- Main geometrical parameters
- Stress dupability
✓Shaft
- Diameters of main parts
- Stress dupability
- Firmness
✓Bearing : choose the needed bearing and check
✓Lubrication
76
Cardan Shaft
➢Cardan Shaft overview
➢Structure of Cardan Shaft
➢Cardan Shaft design

➢Design of cross match
➢Shaft Design
77
Cardan Shaft
➢ Function: connect 2 rotation shafts
1. Gearbox
2. Cross match
3. Active axle
4. Hub
5. Middle bearing
6. Active shaft with
outside working
device
7. Distribution gearbox
8. Final drive
9. Synchronous joint
10. Active wheel
78
Cardan Shaft
➢ Classification: by 2 marks
- By the kinematic of shafts: Synchronous and unsynchronous
- By joint: cross match joint, expansion joint, hard coupling,..
➢ Requirements
- Synchronous shafts speed
- Hight efficiency
- Noise and hardness
- Longevity
79
Cardan Shaft
➢Cardan Shaft Structure
1. Spigot 7. Yoke flange

2. Bearing cover 8. Felt washer
3. Needle rollers 9. Sliding end lubricator
4. Sliding end 10. Star piece
5. Dust cover 11. Relief valve
6. Lock strap 12. Gasket and retainer
80
Cardan Shaft
Cardan
Joints
81
Cardan Shaft
Cardan Joints:
Bendix-Weiss
82
Cardan Shaft
Cardan Joints:
Rzeppa
83
Cardan Shaft
Cardan shaft kinematic
84
Cardan Shaft
➢Cardan Shaft Design
Cardan shaft cross match
Load:
Cross section Cross section
Bending stress Bending stress
Cutting stress Cutting stress
85
Cardan Shaft
Cardan shaft max speed
Centrifugal force:
E: Young’s modulus,
Elastic force: L: shaft length, m
m: shaft mass, kg
J: inertial moment, m4
C: coefficient
Force balance:
If shaft will be broken
Limited speed:
86
Cardan Shaft
Solid shaft Hollow shaft
Cardan shaft max speed
Normal structure
Design note:
87
Cardan Shaft
Cardan shaft calculation
1. Max. torque: Mt=Memax* h; i

2. Determine diameters D and d by stress condition when loading Mt
or
88
Cardan Shaft
Cardan shaft calculation
3. Calculate and check the limited speed of shaft
Vmax – max. speed of vehicle, it-b: ratio from cardan shaft to wheel
4. Calculate the max. length of cardan shaft
89
Final driver and differential

➢Final driver overview
➢Structure of Final driver
➢Final driver design

➢Design of Final driver
➢Shaft Design
90

➢ Function: Make a ratio in order to increase the wheel torque
➢ Requirements
➢ Vehicle dynamic and fuel consumption with the chosen ratios
➢ Hight efficiency and low noise and vibration
➢ Make sure the ground clearance is large enough
➢ Make sure the firmness of structure (bearings and shafts
➢ Classification
➢ Single final driver
➢ Double final driver
➢ “wheel” driver
91

➢ Classification
➢ Single final driver
92

➢ Classification
➢ Double final driver
93

➢ Classification
➢ “wheel” driver
94

➢ Classification
➢ External “wheel” driver
95

➢ Caused by E, kinematic will be wrong→
Slipping→ Hight friction → lubrication
Tangential forces:
Comparison conical gear and hypoid gear
96

Forces in hypoid gear
➢ Hypoid gear design
r1 – radius of small end

b - length of gear
97

➢ Hypoid gear design
Forces on active gear
Tangential Forces
Axial Forces
Radial Forces
Forces on passive gear
Tangential Forces
Axial Forces
Radial Forces
98

➢ Geometrical gear parameter
➢ E <0.2*de2 for passenger car

➢ E<0.125de2 for truck and bus Forces in hypoid gear
99

➢Differential design
Kinematic:
Dynamic:
straight motion:
turn on:
1. Block differential
Poor escape ability Solution 2. Increase friction
3. Control differential
100

➢Differential design
Differential Braking Coefficient Differential Locking Coefficient
Max. traction force

Driver shaft design

➢Classification
a) Fully floating
b) Three-quarter floating
c) Semi-floating
X: Longitudinal force, Y: lateral force, Z: vertical force

Driver shaft design

➢Fully floating shaft design
- Determine the main parameters of shaft by loading: d and L
- Check the durability by torsion stress and angle: τ and θ
Driver shaft design

➢Semi-floating shaft design
Motion with
Motion with
Motion with Passenger car

Truck and bus
Special vehicle
Active axle housing design

➢Rear active housing
Active axle housing design

➢Rear active housing
1- Loading on axle:
- Vertical force: Zi
- Longitudinal force: Xi (traction and
braking)
- Lateral force: Yi
2- Calculation:
a) Moving with Xmax;
b) Moving with Ymax;
c) Moving with Zmax;
THANK YOU !
107

Chapter 4 - Transmissions and Driveline - Clutch

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Chapter 4 - Transmissions and Driveline - Clutch

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MODERN AUTOMOTIVE DESIGN

Le Van Nghia, PhD

• Give examples of common clutch, gearboxes and

• Indicate the terminology and methods for transmission

• Aid the designer to understand the elements of the

What the vehicle requires from the transmission

✓ Letting the vehicle stop by disconnecting the drive when appropriate.

✓ Enabling the vehicle to start at varied rates, under a controlled manner.

✓ Varying the speed ratio between the engine and wheels.

✓ Allowing this ratio to change when required.

✓ Transmitting the drive torque to the required wheels.

• Double-Plate Clutch – Advantages and Disadvantages?

• Dry clutch with diagram spring, coil spring, conical spring

• Automatic or semi-automatic Dry clutch, manual clutch

Advantages and Disadvantages ?

Solo Adjustment-Free Heavy Duty Clutch

Working scheme of Clutch system

Clutch manipulating mechanism

a) Diaphragm spring b) coil spring c) conical spring

Diaphragm spring coil spring conical spring

Memax – engine max. torque

ᵦ- reserve coefficient - Passenger car, commercial car

✓ Number of friction discs;

✓ The dimensions of the friction disc;

✓ Required pressure force;

✓ Number of springs, force of a spring;

✓ Dampers (springs, friction plates).

– small passenger car

– if ne – fast engine (petrol engine), choose r smaller

check pressure on the friction surfaces:

Engage process Engage process modelling

𝐼𝑎 ∗ 𝜔𝑎ሶ = 𝑀𝑐 − 𝑀𝜓 = 𝑘 ∗ 𝑡 𝜔𝑎 = 0.5 ∗ 𝑘 ∗ 𝑡 2 /𝐼𝑎

ωM, ωN – engine speed at max. torque and max. power

Vehicle type Ψ Gear number Limited of Specify Slipping

c = 481,5 J/kg.○C - specific heat capacity of steel

Force for disengage:

Choose the number of pressure spring Zlx: Characteristic of coil spring

FN – force at pressure plate

Number of diaphragm spring blades: 8-20

Damp spring: D/d=4.5-5.5, where D – spring diameter, d- diameter of coil

Damp spring: D/d=4.5-5.5, where D – spring diameter, d- diameter of coil

Zdm – fork number

Cut and bearing (stamping) stresses

Calculation of Rivets, which connect

Calculation Method is the same, but the limited

Clutch shaft = Gearbox

Hydraulic with vacuum

Choose dimensions a,b,c by real structure

- Choose a,b,c and calculate

- Divide the pedal force:

- Force from cylinder:

Main final driver

- Translate power by 2 couple gear

For speed V → choose iT → ne with minimum ge

✓Bearing : choose the needed bearing and check

➢Structure of Cardan Shaft

➢Cardan Shaft design

1. Spigot 7. Yoke flange

Cross section Cross section

Bending stress Bending stress

Cutting stress Cutting stress

If shaft will be broken

Solid shaft Hollow shaft