Structural and thermal analysis of single plate friction ... · Keywords: -Clutch, NX NASTRAN 10.0 Software, structural analysis, thermal analysis. I. INTRODUCTION Clutch is used

International Journal of Technical Innovation in Modern Engineering &

Science (IJTIMES) Impact Factor: 5.22 (SJIF-2017), e-ISSN: 2455-2585

Volume 4, Issue 7, July-2018

IJTIMES-2018@All rights reserved 985

Structural and thermal analysis of single plate friction clutch with different

materials

1M.VENUGOPAL NAIDU,

2 Dr. M.L.S.DEVA KUMAR

1PG Research Scholar, Product design, Mechanical Engineering, JNTUA College of Engineering, Ananthapuramu,

Andhra Pradesh, India 2Professor of Mechanical Engineering, JNTUA College of Engineering, Ananthapuramu, Andhra Pradesh,

India

Abstract—Clutch is a device used in the transmission system of a vehicle to engage and disengage the transmission

system from the engine. Thus the clutch is located between the engine and the transmission system. In a vehicle, the

clutch is always in the engaged position. The clutch is disengaged when starting the engine, when shifting gears,

when stopping the vehicle and when idling the engine. A single plate clutch consists of a clutch plate whose both sides

are faced with a frictional material and it is mounted on the hub. The pressure plate is mounted inside the clutch body

which is bolted to the flywheel.Generally clutches are manufactured by Cast Iron. It is however, highly susceptible to

corrosion (rusting) when exposed to moisture. In order to reduce corrosion cast iron can be replaced with various

composite materials. The aim of the project is to model a single plate clutch and perform static & Thermal analysis by

applying frictional force and temperatures produced by friction. In the presence of torque and speed of engine will

base on the coefficient of friction and mean radius. These are the main parameters in the clutch plate .If increasing

the dia. of the clutch plate the design will be complicated so, by the changing of clutch plate material increasing the

efficiency and Torque. Modeling and Analysis of component is done in NX 10.0 Software.

Keywords: -Clutch, NX NASTRAN 10.0 Software, structural analysis, thermal analysis.

I. INTRODUCTION

Clutch is used in transmission system of any vehicle for disengage and engage to transmission system from the engine.

Therefore clutch is located between the transmission system and engine. The clutch will be in disengaged when the

vehicle getting to be started, whenchanging the gears, when engine ideal condition and when the vehicle is to be stopped.

We know vehicle tends to move the clutch will be kept in engaged position and the vehicle starts to move the clutch will

be engaged. While proper working of the clutch, loads take gradually which reduces uneven condition of vehicle and as

well as strain on its motion it prevents sudden motion of the vehicle and avoids under strain on the remained components

of the transmission of power

Nowadays clutch plates are manufactured with ceramics and found in racing, power boats and automatic gear boxes.

When breaks are failed we can control the speed of vehicle by using clutch pedal while changing gears. Majorly Two

kinds of clutches are used in automobile i.e., Friction clutches and Fluid Flywheel clutches. While designing friction

clutch plates the coefficient of friction is key parameter.

II. LITERATURE SURVEY

[1]Asst. Prof. M.MuraliMohan, B.Sreevani: A friction Clutch is a machine member in power transmission system. It

can be used to connect the engine (driving shaft) to power transmission system (driven shaft), so that the engine may be

start or stop without stopping the power transmission system. A clutch can provides the interruptible linkage provide to

two rotating shafts that are driven shaft and driving shaft respectively. Majorly the Cast Iron and aluminum alloys

materials are used for friction disc. In this concept the cast-iron and aluminum replaced by using composite materials and

perform the structural analysis and dynamic analysis. Depending upon strength to weight ratio the composite material

will be selected. E-Glass Epoxy and Aluminum alloy are taken as composite materials in this project. A friction clutch is

modeling by using PRO-E CREO 2.0 software. The performing the Static analysis and Dynamic analysis on friction

clutch to find out deformations, stresses and may comparing the resultants between materials Aluminum alloy 7075,E

Glass Epoxy and Grey cast-iron. Finite element analysis performed by using the ANSYS software. Theoretical

calculations for friction clutch for determining the deformations and stresses. Then theoretical and simulated values are

compared.

International Journal of Technical Innovation in Modern Engineering & Science (IJTIMES) Volume 4, Issue 7, July-2018, e-ISSN: 2455-2585,Impact Factor: 5.22 (SJIF-2017)


[2] Mr. J. VishalDeshbhratar, Mr. U. NagnathKakde: The main concept about design of friction clutches in

automobile to study the familiarity on the thermo-elasticity is edifying in the initial design stage. There should be a

precise forecast technique in order to know maximum structural stressesinduced in mechanical clutches their fore

resilience and compactness will be obtained. In this process the numerical method and mainframe modeling are

developed by designing the mechanical clutches with help of technique in consistent analysis. In this paper the stress

analysis of friction clutches are discussed. The entire part in this document explains about friction clutches. The PRO-

E(CREO) software can be used for modeling of friction clutch assembly parts. They performed the finite element

analysis in ANSYS and calculated stresses and strains for friction clutch assembly.

III.SINGLE PLATE FRICTION CLUTCH

The more power will be utilized by the circular plate of friction clutch is located between clamping plate and the

flywheel. Inside face of flywheel used for gripping the clutch depends on clamping levers actuate by the spring. The

clamping force in terms of pressureapplied on clutchplate at pivot end.

Fig1. Single Plate Friction Clutch

In order to disengage the clutch, the pedal at the drivers foot is made to compress the clutch spring, pull back the inner

end of clamping levers. This clutch runs in a bath of oil, which prevents the plates gripping too fiercely, due to the fact

that it takes an appreciable amount of time for the oil to be squeeze out from connecting the plates, it takes up the drive

smoothly without shock.

Mainly there are three components in clutch assemblythey are pressure plate, a friction disc and engine flywheel. We

know that the engine runs and rotation of flywheel, automatically the rotation of pressure plate, it can be attach to the

flywheel. Releasing of clutch take place while the driver getting an application of load on clutch pedal. By the application

of pressure plate force will moves against to the friction disc. This forms gaps of air in between friction disc and flywheel

and between the pressure plate and fly wheel. The clutch does not transmit the power.

IV. NX NASTRAN 10.0 Software

This software gives explanation about industrial design, graphic simulation, advanced analysis, concurrent engineering,

geometric modeling and knowledge-based principles. This software consists of modeling in powerful hybrid capabilities

by integrating modeling in constraint-based feature and it explicit the geometric modeling. Standard geometry parts in

modeling will allows to the user to complex free-form shapes in design such as manifolds and airfoils. Solid and surface

modeling powerful tool techniques set to do in this software.

This CAE/CAE/CAD software for product development to be integrated and its gives near to the exact solution, this

software is most advanced in this world. Spanning product development entire range and the software total sizes

enterprises in delivers immense value. The products introducing to the market and the process of complex product design

simplifies by using this software. In the assembly modeling, finite element analysis and machining process this type of

components used later on. The component files are use from online after downloading. The basic software for this

software is Uni-graphics 18 and gives the first tutorial gives on this software’s only, later on it can be updated to NX 2

this followed by the updates for NX 3, NX 5, NX 7, and NX 9 and further updates written-up for NX 10.The analysis of

fluid flow and structural is done by using NASTRAN, COMSOL, ABAQUS and ANSYS, based on different proposes

used suitable software’s respectively.



FEA is one of method for predicting the response of structures and environmental factors for materials that are heat,

vibration and forces. The geometric model creation is the first process in FEA analysis. The meshed (considering into

small elements) model in the structure of geometric shapes connected to the nodal points. The relationships between

stress-strain approximated values are obtained. The behavior of material and also the boundary conditions are applied to

each element. Software such as NX NASTRAN 10.0 used to calculation for complex shapes in simple manner. It can

provide deep insights in the engineering regarding the behavior of objects. The applications of FEA are Structural

Analysis, Thermal Analysis, Fluid Flow Dynamics, and Electromagnetic Compatibility. Of these, performing the

thermal, structural analysis and solid mechanics applications for calculating stresses displacements and nodal

temperatures by using FEA in NX 10.0. The hardware performance in critical conditions used to predict the failures. In

this process the structural stress and strain analysis of solid geometries obtained.

V. STRUCTURAL AND THERMAL THEORITICAL CALCULATION FOR SINGLE PLATE FRICTION

CLUTCH

I.STRUCTURAL THEORITICAL CALCULATION FOR SINGLE PLATE FRICTION CLUTCH

Actual data:

Outer radius (r1):0.09 m

Inner radius (r2):0.0625m

Pressure intensity of the clutch: 300 KN/m2

A.TUNGSTEN CARBIDE MATERIAL:

Co-efficient of friction (µ): 0.8

Uniform pressure intensity (W): =𝜋p (r12-r2

2)

=π (300)* (103) ((0.09)

2-(0.0625)

2)

W =3952.5 KN

Effective mean radius(R): R =2/3[(r13-r2

3)/ (r1

2-r2

2)]

= 2/3[((0.09)3-(0.0625)

3)/ ((0.09)

2-(0.0625)

2)]

= 0.077 m

Torque transmission capacity (T) =µWR

=0.8(3952.51) (0.077)

T =243.47 N-m

B. NICKEL MATERIAL:



2)

=π (300)* (103) ((0.09)

2-(0.0625)

2)

W =3952.5 KN


3)/ (r1

2-r2

2)]

= 2/3[((0.09)3-(0.0625)

3)/ ((0.09)

2-(0.0625)

2)]

= 0.077 m


=0.9(3952.51) (0.077)

T =273.90 N-m



C. KEVLAR 49 MATERIAL:



2)

=π (300)* (103) ((0.09)

2-(0.0625)

2)

W =3952.5 KN


3)/ (r1

2-r2

2)]

= 2/3[((0.09)3-(0.0625)

3)/ ((0.09)

2-(0.0625)

2)]

= 0.077 m


=0.51(3952.51) (0.077)

T =155.21 N-m

D. ALUMINIUM-MILD STEEL ALLOY MATERIAL:



2)

=π (300)* (103) ((0.09)

2-(0.0625)

2)

W =3952.5 KN


3)/ (r1

2-r2

2)]

= 2/3[((0.09)3-(0.0625)

3)/ ((0.09)

2-(0.0625)

2)]

= 0.077 m


=0.61(3952.51) (0.077)

T =185.64 N-m

E. E-GLASS EPOXY MATERIAL:



2)

=π (300)* (103) ((0.09)

2-(0.0625)

2)

W =3952.5 KN


3)/ (r1

2-r2

2)]

= 2/3[((0.09)3-(0.0625)

3)/ ((0.09)

2-(0.0625)

2)]

= 0.077 m


=0.51(3952.51) (0.077)

T =155.21 N-m



Table 1.Theoretical calculation of torque transmission for different materials.

II. THERMAL THEORITICAL CALCULATION FOR SINGLE PLATE FRICTION CLUTCH

Specifications:

Power = 54.4 KW @ 4700 rpm

Torque = 202.5 N-m @ 2800 rpm

Outer radius (r1) =0.09 m

Inner radius (r2) = 0.0625 m

Maximum pressure in terms of Mpa or N/mm2

Area of friction pads (A) = π (r12-r2

2)

= π ((0.09)2-(0.0625)

2)

=0.013 m2

Angular velocity (ω) =2πN/60

= (2π*2800)/60

=293.21 rad/sec.

A. TUNGSTEN CARBIDE (µ=0.8)

Heat generation in watts Qg= coefficient of friction*maximum pressure *angular velocity

= µ*pmax*ω

=0.8*0.3044*293.21

=71.40 watts

Heat flux obtained in clutch plate (Qf) = heat generated in clutch plate/surface area

= Qg/A

= 71.40/0.013

= 5492.49 watt/m2

= 0.005492 watt/mm2

MATERIAL

COEFFICIENT OF

FRICTION(µ)

TORQUE TRANSMISSION

(N-m)

TUNGSTEN CARBIDE

0.8

243.47

NICKLE

0.9

273.90

KEVLAR 29 OR 49

0.51

155.21

Al – MILD STEEL

0.61

185.64

E-GLASS EPOXY

0.51

155.21



B. NICKEL MATERIAL (µ=0.9)

Heat generation in watts (Qg = µ*pmax*ω

=0.9*0.270*293.21

=71.2 watts

Heat flux obtained in clutch plate (Qf)= Qg/A

= 71.2/0.013

= 5480.77 watt/m2

= 0.005480 watt/mm2

C. KEVLAR-49 MATERIAL

Heat generation in watts (Qg)= µ*pmax*ω

=0.51*0.477*293.21

=71.32 watts

Heat flux obtained in clutch plate (Qf) = Qg/A

= 71.32/0.013

= 5486.86 watt/m2

= 0.005486 watt/mm2

D. ALUMINIUM ALLOY 6061 A

Heat generation in watts (Qg)= µ*pmax*ω

=0.61*0.399*293.21

=71.36 watts

Heat flux obtained in clutch plate (Qf) = Qg/A

= 71.36/0.013

= 5489.56 watt/m2

= 0.005489 watt/mm2

E. E-GLASS EPOXY

Heat generation in watts(Qg) = µ*pmax*ω

=0.51*0.477*293.21

=71.32 watts

Heat flux obtained in clutch plate (Qf) = heat generated in clutch plate/surface area

= Qg/A

= 71.32/0.013

= 5486.86 watt/m2

= 0.005486 watt/mm2



MATERIAL

COEFFICEINT OF

FRICTION

MAXIMUM PRESSURE IN

MPA OR (N/MM2)

HEAT FLUX (QF)

(WATT /MM2)

TUNGSTEN

CARBIDE(WC)

0.8 0.304 0.005492

NICKEL MATERIAL 0.9 0.270 0.005480

KEVLAR 49 0.51 0.477 0.005486

ALUMINIUM ALLOY 0.61 0.399 0.005489

E-GLASS EPOXY 0.51 0.477 0.005486

Table 2.Theoretical calculation of heat flux for different materials.

VI. STRUCTURAL AND THERMAL ANALYSIS OF SINGLE PLATE FRICTION CLUTCH

I. SINGLE PLATE FRICTION CLUTCH STRUCTURAL ANALYSYS RESULTS

MATERIALS USED FOR STRUCTURAL ANALYSYS

TUNGSTEN CARBIDE(WC)

NICKEL

ALUMINIUM ALLOY 6061A

KEVLAR 49

E-GLASS EPOXY

These are the materials considering for doing structural analysis. The resultant of each material in structural analysis is

given below clearly.

IMPORTED MODEL INTO NX NASTRAN 10.0 FOR EVERY MATERIAL ANALYSYS

Imported model into NX NASTRAN 10.0 software Meshed body of friction plate in NX NASTRAN 10.0

Pressure load applied on friction plate in NX NASTRAN Fixed constraint in friction plate in NX

NASTRAN

Actual data:



Pressure intensity of the clutch: 300 KN/m2



A. TUNGSTEN CARBIDE (µ=0.8)

Displacement takes place in NX NASTRAN for TUNGSTEN CARBIDE Von-mises Stress takes place in NX NASTRAN for TG

B.NICKEL MATERIAL (µ= 0.9)

Displacement takes place in NX NASTRAN for NICKEL MATERIAL Von-mises Stress produced in NX NASTRAN for

NICKEL MATERIAL

C. ALUMINIUM ALLOY 6061A (µ= 0.61)

Displacement takes place in NX NASTRAN for AL ALLOY 6061A Von-mises Stress produced in NX NASTRAN for AL ALLOY

6061A

D. KEVLAR 49(µ= 0.51)

DISPLACEMENT takes in NX NASTRAN for KEVLAR 49 Von-mises stress produced in NX NASTRAN for KEVLAR 49



F. E-GLASS EPOXY (µ=0.51)

DISPLACEMENT takes place in NX NASTRAB for E-GLASS EPOXY Von-mises STRESS produced in NX NASTRAN for E-

GLASS EPOXY

MATERIAL

COEFFICIENT OF

FRICTION(µ)

PRESSURE

LOAD(KN/m2)

VON-MISES

STRESS(Mpa)

DISPLACMENT

AT NODAL

MAGNITUDE(mm)

TUNGSTEN

CARBIDE(WC)

0.8

300

0.728

3.2716E-006

NICKEL

0.9

300

0.728

9.8148E-006

ALUMINIUM

ALLOY 6061A

0.61

300

0.719

2.856E-005

KEVLAR 49

0.51

300

0.705

1.5233E-005

E-GLASS EPOXY

0.51

300

0.714

7.3115E-006

Table 3. Structure analysis results comparison

II. SINGLE PLATE FRICTION CLUTCH THERMAL ANALYSYS RESULTS

MATERIALS USED FOR THERMAL ANALYSYS

TUNGSTEN CARBIDE(WC)

NICKEL

ALUMINIUM ALLOY 6061A

KEVLAR 49

E-GLASS EPOXY

These are the materials considering for doing thermal analysis. The resultant of each material in thermal analysis is given

below clearly.

IMPORTED MODEL INTO NX NASTRAN 10.0 FOR EVERY MATERIAL ANALYSYS

Imported model into NX NASTRAN 10.0 software Meshed body of friction plate in NX NASTRAN 10.0



BOUNDARY CONDITIONS

Heat flux given as load on friction plate in NX NASTRAN Convection Constraint Fixed in friction plate in

NX NASTRAN

Actual data:



Heat flux density of the clutch: 0.006 Watt/mm2

A. TUNGSTEN CARBIDE (µ= 0.8)

Nodal temperature takes place in NX NASTRAN Elemental gradient temperature takes place in

NX NASTRAN

Elemental heat flux takes place in NX NASTRAN for TUNGSTEN CARBIDE

B. NICKEL MATERIAL (µ= 0.91)

Nodal temperature takes place in NX NASTRAN Elemental gradient temperature takes place in NX NASTRAN



Elemental heat flux takes place in NX NASTRAN for NICKEL MATERIAL

C. ALUMINIUM ALLOY 6061A (µ= 0.61)

Nodal temperature takes place in NX NASTRAN Elemental gradient temperature takes place in NX NASTRAN

Elemental heat flux takes place in NX NASTRAN for ALUMINIUM ALLOY

D. KEVLAR 49 (µ=0.51)

Nodal temperature takes place in NX NASTRAN Elemental gradient temperature takes place in

NX NASTRAN



Elemental heat flux takes place in NX NASTRAN for KEVLAR 49

E. E-GLASS EPOXY

Nodal temperature takes place in NX NASTRAN Elemental gradient temperature takes place in NX

NASTRAN

Elemental heat flux takes place in NX NASTRAN for E-GLASS EPOXY

MATERIAL HEAT FLUX

(Watt/mm2)

NODAL

TEMPERATURE

(0C)

ELEMENTAL

GRADIENT

TEMPERATURE(0C/mm)

ELEMENTAL

HEAT FLUX

(W/mm2)

TUNGSTEN

CARBIDE(WC)

0.006

51.670

0.533

0.059

NIKEL

MATERIAL

0.006 53.072 0.645 0.059

ALUMINIUM

ALLOY

0.006 49.076 0.326 0.0586

KEVLAR 49 0.006 63.343 1.466 0.059

E-GLASS EPOXY 0.006 45.565 0.045 0.058

Table 4.Thermal analysis results comparison



VIII. CONCLUSION:

In single plate friction clutch, the friction facing plate plays major important role in torque transmission from engine to

transmission system. Clutches are in engaged with flywheel, by pressing clutch pedal it will be disengaged & at that

situation sudden increase in temperature. The material wear out due to friction produced between mating parts. When

some force is acting on clutch disc there must be some deformation due to temperature variation & stresses developed in

clutch disc. That temperatures and stresses should be within the limits.

In this project the modeling of friction facing plate and performing the structural and thermal analysis by changing

friction material by using NX NASTRAN software following results are drawn. The Von-mises stresses calculate for

Tungsten carbide, Nickel material, Aluminum alloy 6061A, Kevlar 49 and E-glass epoxy composite as a facing material.

Structural and thermal analysis is done to determine stresses for all the friction materials. The stresses for above

mentioned material for friction facing component is nearly same. Capacity of Torque transmission for Nickel material is

more when compared with other friction materials and also Nickel material withstands high temperature and pressure.

By observing the analysis result in NX NASTRAN 10.0 software, so it can be concluded that by theoretical and

analytical results according to NX NASTRAN 10.0 Software Nickel material is best for friction facing material.

IX. ACKNOWLEDGEMENT

We would like to thank all the authors of different research papers referred during writing this paper. It was very

knowledge gaining and helpful for the further research to be done in future.

X. REFERENCES

[1] Design and Analysis of Clutch Using Sintered Iron as a Friction Material by Mamta G. Pawar, Monarch

K.Warambhe, GautamR.Jodh, International Journal of Innovative Technology and Exploring Engineering (IJITEE),

ISSN: 2278-3075, Volume-3, Issue-7, December 2013

[2] Dynamic Analysis Of Single Plate Friction Clutch by Shrikant V. Bhoyar, Dr. G. D. Mehta, Dr.J.P.Modak,

International Journal of Engineering Research and Technology, ISSN: 2278-0181

[3] Static Structural Analysis of Multi-plate Clutch with Different Friction Materials by Anil Jadhav, Gauri Salvi,

Santosh Ukamnal, Prof. P. Baskar, , International Journal of Engineering Research and Technology, ISSN: 2278-0181

[4] Optimal Design of a Clutch Plate using Ansys by V Mani Kiran Tipirineni, P. Punna Rao, International Journal Of

Computational Engineering Research (ijceronline.com) Vol. 03 Issue. 12

[5] Thermo‐mechanical Analysis of the Dry Clutches under Different Boundary Conditions by O.I.Abdullaha,

Schlattmanna, A.M.Al‐Shabibi, Vol.36,No.2(2014)172‐180, Tribology in Industry

[6] Modeling and assembly of single plate friction clutch of an automobile by Prafull. S. Thakare , Vishal J. Deshbhratar

AND Abhinav. P. Ninawe, Indian Streams Research Journal, Volume: II, Issue: II, March – 2012

[7] Dynamic analysis of single plate friction clutch by Shrikant V. Bhoyar, G.D. Mehta, J.P. Modak

Structural and thermal analysis of single plate friction ... · Keywords: -Clutch, NX NASTRAN 10.0 Software, structural analysis, thermal analysis. I. INTRODUCTION Clutch is used

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