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Journal of Technological Advances & Scientific Research/ eISSN- 2454-1788, pISSN- 2395-5600/ Vol. 1/ Issue 04/ Oct-Dec. 2015 Page 366

OPTIMAL DESIGN AND ANALYSIS OF MULTI FRICTION PLATES USING CREO AND FEA PACKAGE Pulavarthi Krishram Raju1, P. Siva Subramanyam2, K. N. D. Malleswara Rao3

1Post Graduate Student, Department of Mechanical Engineering, Nova College of Engineering and Technology, Ibrahimpatnam. 2Associate Professor, Department of Mechanical Engineering, Nova College of Engineering and Technology, Ibrahimpatnam. 3Assistant Professor, Department of Mechanical Engineering, Nova College of Engineering and Technology, Ibrahimpatnam.

ABSTRACT: Clutch is one of the essential components in automobiles. It is located between the engine and the gear box. The main

function of the clutch is to initiate the motion or increase the velocity of the vehicle by transferring kinetic energy from the flywheel.

Multiplate clutch is one of the important parts in the power transmission systems. Good design of clutch provides better system

performance. Multiplate clutch is widely used in racing cars and heavy duty vehicles, which have space limitations and require high

torque transmission. In this paper a pressure plate of multiplate clutch has been designed by using empirical formulae. This work

depicts a solid modelling of pressure plate with CREO package that is employed for varied automotive applications. The structural

analysis of clutch plate is done over different materials. The analysis is carried out on FEA package to get the foremost appropriate

material for pressure plate of clutch. From the analyzed results, stress, strain and total deformation values were compared for all the

three materials and the best one was taken out and the best material with good model will suggest to the company.

HOW TO CITE THIS ARTICLE: Pulavarthi Krishram Raju, P. Siva Subramanyam, K. N. D. Malleswara Rao. “Optimal Design and

Strength Analysis of a Wheel Hub by using different Materials.” Journal of Technological Advances and Scientific Research;

Volume 1, Issue 04, October-December 2015; Page: 366-372, DOI: 10.14260/jtasr/2015/51.

INTRODUCTION:

Introduction to Clutch: Transmission is the mechanism

which is used to transfer the power developed by engine to the

wheels of an automobile. The transmission system of an

automobile includes clutch, gear box, propeller shaft axle and

wheels, etc. Description of various types of clutches and gear

boxes has been given in the following sections of this unit. The

term ‘Transmission’ is used for a device, which is located

between clutch and propeller shaft.

A clutch is that part of engine, which engages or

disengages power from the engine crankshaft to transmission.

Clutch is a machine member used to connect the driving shaft

to a driven shaft, so that the driven shaft may be started or

stopped at will without stopping the driving shaft. A clutch

thus provides an interruptible connection between two

rotating shafts and allow a high inertia load to be stated with a

small power.

Fig. 1: Clutch Plates

Financial or Other, Competing Interest: None.

Submission 15-12-2015, Peer Review 17-12-2015 Acceptance 22-12-2015, Published 26-12-2015. Corresponding Author: Pulavarthi Krishram Raju,

S/o. Prabhudasu, 1-59, Nagapuram (v), Dosapasu (Post), Krishna.

E-mail: [email protected] DOI:10.14260/jtasr/2015/51.

Principle of Clutch: It operates on the principle of friction.

When two surfaces are brought in contact and are held against

each other due to friction between them, they can be used to

transmit power. If one is rotated, then the other also rotates.

One surface is connected to engine and other to the

transmission system of automobile. Thus, clutch is nothing but

a combination of two friction surfaces.

Fig. 2: Position of Friction Plate

Main Parts of Clutch:

a) Driving member,

b) Driven member.

Driving Member: Driving member has a flywheel, which is

mounted on the engine crankshaft. A disc is bolted to flywheel,

which is known as pressure plate or driving disc.

Driven Member: The driven member is a disc called clutch

plate. This plate can slide freely to and fro on the clutch shaft.

The operating member consists of a pedal or lever, which can

be pressed to disengage the driving and driven plate. There are

several types of clutch plates available, which are divided into

external and internal tooth and the most commonly used

materials for the clutch plates are steel and for friction

material cerametallic or like material, which is named as

Kevlar and it is a composite material. As in brakes a wide range

KEYWORDS: ANSYS, Creo, Friction Plate, FEA Package.



of clutches are in use, wherein they vary in their working

principle as well the method of actuation and application of

normal forces. The discussion here will be limited to

mechanical type friction clutches or more specifically to the

plate or disc clutches also known as axial clutches. Clutch plate

is part of series of discs inside of a transmission. The clutch

plate is round and has a friction sensitive surface that allows it

to grip. It sits next to the fly wheel, which is connected to the

drive shaft permanently. That means the flywheel immediately

starts to spin as soon as the engine is turned on and the motor

turns the crankshaft. When this happens in a manual

transmission, the clutch must be disengaged. That is it is pulled

back from the flywheel, so it can spin without engaging the

wheels.

TWO WHEELER CLUTCH PLATES:

Clutch Friction Disc 2-wheeler: Two Wheeler clutch friction

disc also called as friction lining is made up of a splined round

metal part plate covered with friction material (lining). The

splines in center of the clutch disc mash with splines on the

input shaft of manual transmission. This makes the input shaft

and disc turn together. However, the disc is free to slide back

and forth in the shaft.

Clutch Friction Disc Cork and Paper Base: Cork base clutch

is made up of heat resistant non-asbestos cork and fibers.

Grooves are cut into friction material to aid cooling and

releasing clutch disc. In 4 wheeler clutches, the rivets are used

to hold the friction material to both sides of the metal body of

the disc.

Paper base clutch friction disc is made up of heat-resistant

cellulose based material molded together. Cellulose is used to

prolong life of the clutch and provide more torsional strength.

Paper clutch friction disc has more life than cork base friction

materials as it possess:

More heat resistant property.

Low wear and tear characteristics.

High endurance.

At MK we make clutch as required by our customers with

meeting international standards in any design and with any

friction material technology.

Fig. 3: Two Wheeler Clutch Plates

CLASSIFICATION OF CLUTCHES

Friction Clutch:

a. Single plate clutch,

Fig. 4: Single Plate Clutch

b. Multi-plate clutch, (Multi-plate clutch can be either wet

or dry. A wet clutch is operated in an oil batch, whereas

a dry clutch does not use oil.)

Fig. 5: Multi Plate Clutch

Cone Clutch:

Fig. 6: Cone Clutch

Centrifugal Clutch:

Fig. 7: Centrifugal Clutch


Journal of Technological Advances & Scientific Research/ eISSN- 2454-1788, pISSN- 2395-5600/ Vol. 1/ Issue 04/ Oct-Dec. 2015 68

Semi-Centrifugal Clutch.

Fig. 8: Semi Centrifugal Clutch

Hydraulic Clutch:

Fig. 9: Hydraulic Clutch

Vacuum Clutch:

Fig. 10: Vacuum Clutch

Electromagnetic Clutch:

Fig. 11: Electromagnetic Clutch

MODELLING OF FRICTION PLATE USING CREO:

Fig. 12: Actual Model

Fig. 13: Optimized Models 1

Fig. 14: Optimized Model 2

ANALYSIS USING FEA PACKAGE

Fig. 15: Meshed Actual Model



Fig. 16: Meshed Model 1

Fig. 17: Meshed Models 2

RESULTS AND DISCUSSION

Actual Model

a) Cork

Fig. 18: Total Deformation

Fig. 19: Stress Intensity

b) Carbon–Graphite Powdered Metal



c) Impregnated Asbestos





OPTIMIZED MODEL 1

a) Cork









OPTIMIZED MODEL 2

a) Cork











COMPARISON OF RESULTS

Results of Actual Model

Sl.

No. Material

Stress

Intensity

Total

Deformation

1 Cork .014108 .382E-03

2 Carbon-graphite

powdered .012005 .108E-06

3 Impregnated asbestos .014529 .101E-03

Table 1: Actual Model Results

Results of Optimized Model 1

Sl.

No. Material

Stress

Intensity

Total

Deformation

1 Cork .012072 .373E-03

2 Carbon-graphite

powdered .010921 .101E-06


Table 2: Optimized Model 1 Results

Results of Optimized Model 2

Sl.

No. Material

Stress

Intensity

Total

Deformation

1 Cork .019755 .512E-03

2 Carbon-graphite

powdered .016167 .142E-06


Table 3: Optimized Model 2 Results

CONCLUSION: The total project consists of a design and

analysis of different friction clutch plates using different

materials. For the modelling and analysis, we used creo-2.0

and ANSYS package (FEA package). After the comparison of

results we conclude that,

Considering the criteria of the models

The stress intensity and deformation values are little

better for optimized model-1 compares to actual and

optimized model-2.

And also by considering the criteria of the materials used

we observed that

Carbon graphite powdered material got the good results

compared to other two materials.

So we suggest the companies that by using composite

alloy materials with optimal designed models the life time of

the multiple clutch plates may increase.

Future Scope:

We may reduce the thickness of the friction lining

material of the multiple clutch plates.

We may reduce the weight of the plate by using composite

alloy materials.



REFERENCES:

1. Design and Analysis of clutch using Sintered Iron as a

Friction Material by Mamta G Pawar, Monarch K

Warambhe, Gautam R Jodh.

2. International Journal of Innovative Technology and

Exploring Engineering (IJITEE), ISSN: 2278-3075,

Volume-3, Issue-7, December 2013.

3. Jaya Kishore S, Lava Kumar M. “Structural Analysis of

Multi-Plate Clutch.” International Journal of Computer

Trends and Technology (IJCTT) – volume 4 Issue 7–July

2013.

4. Dynamic Analysis of Single Plate Friction Clutch by

Shrikant V Bhoyar. Dr. GD Mehta, Dr. JP Modak.

International Journal of Engineering Research and

Technology, ISSN: 2278-0181.

5. Jaya Kishor S, Lava Kumar M ― Structural Analysis of

Multi-Plate Clutch―(IJCTT) – volume 4 Issue 7–July 2013

ISSN: 2231-2803.

6. Static Structural Analysis of Multiplate 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.

7. Sankar L, Srinivasan R, Viswanathan P, et al. ―Comparison

study of al-fly ash composites in automobile clutch plates,

International Journal of Emerging trends in Engineering

and Development, Issue 3, Vol. 3 (May 2013), ISSN 2249-

6149.

8. Thermo‐mechanical Analysis of the Dry Clutches under

Different Boundary Conditions by Abdullaha OI,

Schlattmanna, Al‐Shabibi AM.

Vol. 36, No.2 (2014);172‐180, Tribology in Industry.

9. Modelling 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.

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