Design and Analysis of Clutch Lining using different materials

PROJECT REPORT
Submitted by
AHIL PADMAN P I 962913114303
AJEESH A S 96293114304
ANISH XAVIER M 962913114307
ARUN K S 962913114308

In partial fulfillment for the award of the degree

of
BACHELOR OF ENGINEERING
in
MECHANICAL ENGINEERING
VINS CHRISTIAN COLLEGE OF ENGINEERING,
CHUNKANKADAI, NAGERCOIL, KK.DIST
ANNA UNIVERSITY: CHENNAI 600 025
APRIL 2016
ANNA UNIVERSITY: CHENNAI 600 025
BONAFIDE CERTIFICATE

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 Certified that this project report “ Design and Analysis of Clutch
Lining using different materials the bonafide work of
AHIL PADMAN P I 962913114303
AJEESH A S 96293114304
ANISH XAVIER M 962913114307
ARUN K S 962913114308
who carried out the project under my Supervision

SIGNATURE SIGNATURE
Mr.Y.YESU JEBINTH RAJA M.E., (Ph.D) Mr. M.E., (Ph.D)
HEAD OF THE DEPARTMENT SUPERVISOR
Dept. of Mechanical Engg Dept. of Mechanical Engg
VINS College of Engineering VINS College of Engineering
Chunkankadai Chunkankadai
Submitted for the project viva-voce held on ………………….

INTERNAL EXAMINER EXTERNAL EXAMINER

ACKNOWLEDGEMENTS

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 We give all glory to god almighty for all the blessing given as for
completing the phase of my mini-project work successfully in time.
We take this opportunity to express our sincere gratitude and thanks to our
chairman Thiru. NANJIL .M. VINCENT, B.A, B.L ,Ex.M.P for allowing us
to do the project work.
We express our sincere thanks to our principal Dr.
ALEX RAJJU BALAN , M.E., Ph.D for his guidance and support throughout
this project work.
We would like to express our sincere and whole hearted thanks to Head of
the Department Mr .Y. YESU JEBINTH RAJA .,M.E., (Ph.D)
for his supporting untiring efforts and encouragement through the project work.
We extend our sincere thanks to our project guide
Mr. M.E.,(Ph.D)whose inspiration and guidance led me towards successful
completion of the project.
We surrender our esteemed and sincere thanks to the Faculty members of
Mechanical Engineering for their helpful and timely suggestion .
We express our deep gratitude to My Parents who supported us and are the
back bone of our success .
Last but not least I greatful and obliged to all who have directly and
indirectly assisted us in the completion of my project.

ABSTRACT

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 The aim is to design and develop a control system based an electronically
controlled automatic break failure indicator by using IR sensor and engine
over heating alarm by using heat sensor is called “AUTOMATIC BREAK
FAILURE INDICATOR AND ENGINE OVER HEATING ALARM”.

This is consists of IR sensor circuit, heat sensor circuit, control unit and
frame. The sensor is used to detect the break wire. There is any disconnection
of the break wire or cutting of any few turns of break wire, the control signal
to the alarm unit. Similarly the heat sensor is fixed to the engine and this heat
is measured and giving the alarm signal when the engine heat exceeds the set-
temperature limit.

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5
 CONTENTS

 ABSTRACT
 LIST OF TABLE
 LIST OF FIGURE
1. INTRODUCTION 1
2. BLOCK DIAGRAM 2
3. CONSTRUCTION 3
4. WORKING PRINCIPLE 24
5. COST OF ANALYSIS 25
6. ADVANTAGES 26
7. APPLICATIONS 28
8. CONCLUSION 29
9. REFERENCES 30
10 .PHOTOGRAPHY 31

INTRODUCTON

Car safety is the avoidance of automobile accidents or the minimization

of harmful effects of accidents, in particular as pertaining to human life and
health. Special safety features have been built into cars for years, some for the
safety of car occupants only, and some for the safety of others. We have
pleasure in introducing our new project. Which is fully equipped by sensors
circuit, dim bright light and engine over heat alarm circuit. It is a genuine
project which is fully equipped and designed for automobile vehicles.

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 This forms an integral part of best quality. This underwent strenuous test
in our automobile vehicles and it is good. Man has needed used energy at an
increasing rate for its sustenance and well being ever since he came on the
earth a few million years ago. Primitive man required energy primarily in the
form of food. He derived this by eating plants or animals, which he hunted.

Subsequently he discovered fire and his energy needs increased s he

started to make use of wood and other bio mass to supply the energy needs for
cooking as well as agriculture. He added a new dimension to the use of energy
by domesticating and training animals to work for him.

With further demand for energy, man began to use the wind for sailing
ships and for driving windmills, and the force of failing water to turn water
wheels. Till this time, it would not be wrong to say that the sun was supplying
all the energy needs of man either directly and that man was using only
renewable sources of energy.

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 BLOCK DIAGRAM

LED
DISPLAY

WHEEL
DRUM
MICRO
CONTROLLER BUZZER
RELAY

ENGINE

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CONSTRUCTION

The major components of the project are follows

 LDR sensor and heat sensor

 Frame

 Battery

 Dim/Bright light

 Relay

Engine Parts

The engine is the most important part of a vehicle. It contains the parts
which are mechanized to start the engine, convert the fuel energy to kinetic
energy and transmit the power for the proper running of the vehicle.

 Camshaft: Camshaft is a shaft which is equipped with cams that turns in

time with the crankshaft. It opens and holds the valves for a specific
period of time. It also controls the air/fuel mixture entering and exiting
the cylinder.

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  Crankshaft: The Crankshaft translates reciprocating linear piston motion
into rotation. It converts the up and down motion of the piston through a
connecting rod into rotational motion.

 Engine Valves: Valves injects fuel and allows combustion to get out of the
cylinder.

 Kick Lever / Starter: The kick lever is a shaft which has to be 'kicked' to
start the engine.

 Piston: The piston is a circular forging which moves up and down inside
the bore of a cylinder of an engine for the purpose of transmitting power.
The piston converts the potential energy of the fuel into kinetic energy.

 Seal System: Sealing system of a two-wheeler is the sealing arrangement

inside its engine.

 Throttle Cable: Throttle cable is the wire which attaches the throttle to the
carburetor. It helps the operator to be in control of the speed of the
engine.

Camshaft

Camshaft is a shaft which is equipped with cams that turns in time with
the crankshaft. It is used in piston engines to operate poppet valves. It
comprises of a cylindrical rod which runs along the length of the cylinder bank.
It also has a number of lobes or cams originating from it, one for each valve.

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 The engine camshaft is connected to the crankshaft either directly, by a gear
mechanism, or indirectly by a belt or chain called a timing belt or timing chain.

Types of Camshafts:

 Flat-Tappet: More popular and less expensive. It uses a tappet or a lifter.

 Roller-Tappet: Use a roller follower which allows the follower to roll

over the face of the cam lobe. Minimum friction happens with this kind of
camshafts.

Functions of Camshaft

 Opens the valves physically and hold them open for a specific period of
time.

 Controls the air/fuel mixture entering and exiting the cylinder.

 Controls the valve timing and in the process ensures that the intake valves
open at the proper time to feed air and fuel into the engine

 Materials used for making Camshaft

 The most commonly used materials used for making camshaft are:

 Cast Iron

 High Carbon Steel

 Maintenance of Camshaft

 To reduce the friction between the surface of the cam and the cam
follower, lubricants should be used.

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Crankshaft

Crankshaft is the main driving shaft of an engine that receives

reciprocating motion from the pistons and converts it to rotary motion. It
converts the up and down motion of the piston through a connecting rod into
rotational motion. It was invented by Turkish inventor Al-Jazari in the 12th
century.

Functions of Crankshaft

Transforming the piston's reciprocating motion into rotary motion together with
the connecting rod is the main function of the crankshaft.
Characteristics of Engine Crankshaft

 It plays an important role in determining engine power characteristics and

engine power feel.

 Usually, the crankshaft revolves more than 5000 times per minute.

 The crankshaft is the common connecting point of all the pistons in the
engine.

 It revolves at a high speed.

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Engine Valves

Engine Valves are used for closing the combustion chamber and are
installed on the engine cylinder. Efficient sealing of the valves is required in
order to produce compression by the internal combustion engine, which is
basically an air pump.

Characteristics of Engine Valves

 Two Wheeler Engine Valves are almost always round which give the
advantage of rotating harmlessly while in use and can also be lapped in.

 Engine valves are installed on the engine cylinder head to close

combustion chamber.

 Materials used for making Engine Valve

The main criteria for selecting the materials for making engine valves are that it
should be capable of surviving in two highly different operating environments.
Some of most commonly used materials are:

 Titanium

 Aluminum

 Nickel Alloy

 Steel Alloy

Maintenance of Engine Valves

Check for worn valve seals, they are characterized by a puff of blue
smoke from the exhaust when pressing back down on the accelerator pedal
after allowing the engine to over-run, such as when changing gear.

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Kick Lever/Starter

 The Kick Lever/Starter is a shaft which has to be 'kicked' to start the

engine.

Functions of Kick Starter/Lever

 The function of the Kick Lever/Starter is to start the engine.

 Materials used for making Kick Lever/Starter

The materials used for making kick lever/starter should be strong enough
to withstand the weight of the rider who has to put his full weight to kick
start the engine. Some of the materials most commonly used to make kick
lever/starter are:

 Aluminum

 Steel

Maintenance of Kick Lever/Starter

 The transmission kick start shaft can wear with time, it will cause problem
in the operation of the kick starter. In order to minimize this damage, the nut
on the pin should be kept tight.

 The transmission input shaft should be lubricated regularly to minimize

wear.

 When assembling back the kick starter, care should be taken to line them up
right otherwise it will jammed the kick starter. And if the parts are worn out,
they should be replaced.

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Piston

The piston is a circular forging that moves up and down inside the bore of
a cylinder of an engine. It transmits power created by the exploding fuel to the
crankshaft through a connecting rod.

Piston Head/Crown

It is the top surface where the explosive force is exerted. It can be be flat,
concave, convex. Its main function is to promote turbulence or help control
combustion.

Seal System
Though there are many types of sealing arrangements, there are five main
basic parts or elements in a seal system: a dust seal, a stopper ring, an oil seal, a
backup ring and a slider bushing. Each performs a specific function.
 Dust Seal: It consists of a simple rubber or plastic ''grommet'' at the place
where the two halves of shock assembly come together. Its main purpose
is to keep dirt and debris away from reaching the actual oil seal.
 Stopper Ring: Usually, a stopper ring is a ring of steel spring wire or a
large C-clip which is fitted in a machined groove in the shock housing
below the dust seal. Its purpose is to keep the seal below it from being
forced upward and out of position by the force of the springs during
shock compression.

 Oil Seal: The oil seal lies below the stopper ring. Usually, they are made
of steel with a rubber cover. It is usually pressed or ''hammered'' into its
seat in the housing by a specially-fit driver. Its main purpose is to keep
the fluid inside from leaking out and to keep the dirt out.

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  Back-up Ring: The back-up ring is below the oil seal. It looks like a big
washer. The main functions of the back-up ring are to abate the upward
forces against the seal and make them to spread evenly over the sealing
surface. It also protects the seal from the slider bushing being driven too
far up the tube and into the rubber parts.

Clutches

Centrifugal Clutch is based on the principle of centrifugal force. This

clutch uses a combination of friction Discs (like brake shoe) and floater (outer)
to transfer power from the engine to the drive wheels. In all centrifugal clutches,
centrifugal force works against spring tension to determine whether the clutch is
engaged or not. At low rpm, the spring tension is greater than the centrifugal
force and the clutch spins freely. As the engine speed increases, the centrifugal
force begins to overcome the spring tension and at one point of time friction
discs get engaged with floater and transmit the power.

Plate Type Two Wheeler Clutches

Plate Type Clutches consists of set of friction plates & steel plates that are
pressed under the spring load & transmits the power from engine to gearbox
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and subsequently to drive wheels.This clutch is an arrangement of plates
stacked in alternating fashion, one geared on the inside to the engine, and next
geared on the outside to the transmission input shaft. Whether wet or dry, the
plates are squeezed together by a spring, causing friction buildup between the
plates until they rotate as a single unit, driving the transmission directly.

Manual Transmission Four Wheeleer Clutches

Manual Transmission are characterized by gear ratios which are

selectable by engaging pairs of gears inside the transmission. Manual
Transmission is a type of transmission used in automotive applications. Manual
Transmissions often feature a driver-operated clutch and a movable gear
selector, although some do not. Most automobile manual transmissions allow
the driver to select any gear at any time, but some, such as those commonly
mounted on motorcycles and some types of race cars, only allow the driver to
select the next- highest or lower gear ratio.

Automatic Transmission Four Wheeler Clutches

Automatic Transmission also accomplish the same thing as Manual

Transmission But it does in different way. The automatic transmission’s
primary job is to allow the engine to operate in its narrow range of speeds
while providing a wide range of output speeds. In place of clutch, Auto
Transmission uses a torque converter & same set of gear produces all of the
different gear ratios to obtain varying speed of vehicle.There are two big
difference between an automatic transmission and manual transmission:

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  There is no clutch pedal in an automatic transmission car.

 There is no gear shift in an automatic transmission car. Once you put the
transmission into drive, everything else is automatic.

Clutch Friction Disc-Two Wheelers

The clutch friction Disc, also called as friction lining, consists of a

splined round metal plate covered with friction material (lining). 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.

Cork Base & Paper Base Clutch Friction Disc

The cork base clutch friction Disc is made of heat–resistant non-asbestos

cork, cotton fibers and copper wires moulded together. Grooves are cut into the
friction material to aid cooling and release of the clutch Disc. In some cases,
rivets are used to bond the friction material to both sides of the metal body of
the Disc.The paper base clutch friction Disc is made of heat–resistant cellulose,
cotton fibers and copper wires moulded together. Cellulose is used to prolong
life of the clutch and provide more torsional strength. Paper CFD has more life
than cork base friction material as it possess :-

 More heat resistant property

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  Low wear and tear characteristics

 High endurance

 Low warranties

CLUTH TECHNOLOGY

An automobile clutch is a highly sophisticated mechanism that plays an

important role of engaging and disengaging the transmission of motive power
through the medium of clutch Disc lined with friction material.
The running feel of the motor vehicle is largely determined by the
performance.
Characteristics of the clutches.
Clutches vary in their structure and performance characteristics
depending on whether it is an automatic or manual clutch, or whether it is a
Two Wheelers or Four Wheelers clutch.How ever irrespective of their shape or
size, all automobiles clutches involve the use of high level of engineering
technique.
Clutch is a device which helps in transmitting power from engine to the
gearbox and subsequently to the drive wheels.

Need clutch

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 We need a clutch because the engine spins all the time and the vehicle
wheels don’t. For a vehicle to stop without damaging the engine, the power
being transmitted to wheels need to be discontinued from the engine somehow.
The clutch allows to smoothly engage a spinning engine to a non-spinning
transmission by controlling the slippage between them through subjecting itself
to varying degrees.

Throttle Cable

The Throttle Cable is a stiff wire which attaches the throttle to the carburetor. It
slides within a covering. Throttle Cable makes the operator constantly in
control of the speed of the engine.

Functions of Throttle

 Throttle Cable pulls on the throttle position spring which in turn rotates
the throttle pivot.

 It makes the rider to be in control of the speed of the vehicle.

Characteristics of Throttle Cable

 It is a part of a carburetor.

 Throttle Cable controls the throttle valve by connecting it to the

accelerator pedal.

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  A loose throttle cable will cause slow response.

 A too tight cable will lead to excessive fuel consumption.

 There are two different retainers for the throttle cable end inside the
Throttle Tube assembly.

 Materials used for making Throttle Cable

The most commonly used materials for making Throttle Cable are:

 Stainless Steel

 Aluminum

 Maintenance of Throttle Cable

 Throttle pivot should be lubricated regularly.

 Regular check to see if the cables are loose is a must.

 They should checked for kinks and chafing.

Clutch System

A clutch is a mechanism for transmitting rotation, which can be engaged

and disengaged. On most two-wheelers, the clutch lever located on the left
handlebar operates the clutch. When the levers are pulled back, the clutch
plates disengage and allows the rider to shift gears.

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Parts of Clutch System

The clutch system consist of the following parts:

 Clutch Covers

 Clutch Lever

 Clutch Plates

 Clutch Shoes

 Clutch Weights

 Clutch Wire

Functions of Clutch System

The main function of the system is to engage and disengage the engine
from the transmission which enables the driver to start, stop, idle in neutral and
shift gears of a vehicle. While the engine is engaged, engine power flows to the
transmission and engine power cannot flow through to the transmission while
the engine is disengaged.

Maintenance of Clutch System

 Periodic adjustment of the cables are necessary.

 The clutch plates should be replaced whenever the clutch is repaired.

 The lever should be checked for adequate amount of the hydraulic fluid or
whether it needs bleeding. They should also be checked for wear and tear.

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Carburetor

Carburetor was invented by Hungarian scientists Donát Bánki and János

Csonka in 1893. They are responsible for mixing the right amount of air and
fuel to make the engine run.
Types of Engine Carburetors
 There are three main types of Carburetors:
 Butterfly Controlled Carburetor
 Vacuum Controlled Carburetor
 Slide Controlled Carburetor

Functions of Carburetor
The carburetor is responsible for mixing the right amount of gasoline
with air for the proper running of the engine. Too little fuel will either damage
the engine or it will not run. Too much fuel can lead to make the engine run
poorly or it will not run at all.

Maintenance of Carburetor

Proper maintenance of the carburetor is necessary to make the engine

consistent and run smoothly.

 The air filter of the carburetor should be cleaned at regular intervals.

 The carburetor should be aligned properly.

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  The adjustment screws and the high speed needle should be done in a
proper way.

 Dirt is the prime enemy of carburetors. It affects the fuel flow, binds the
slide valve and wear out the inside of the carburetor which can lead to
extra friction and air leaks. In such a case the carburetor has to be
changed.

Parts of a Carburetor

There are seven important parts of a carburetor:

 Air Cleaner

 Choke
 Carburetor Throat and Jets
 Throttle Butterfly
 Needle Valves
 Float or other Regulating System
 Throttle Cable
Exhaust system

The function of Exhaust System of an engine is to discharge the gas

which occurs by the combustion of fuel. Although much of the exhausted gas is
relatively harmless carbon dioxide, part of it comprises of noxious or toxic
substances, such as carbon monoxide, hydrocarbons and nitrogen oxides. A
good exhaust system converts most of the harmful gases into acceptable by-
products.

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Characteristics of Exhaust System

 Exhaust gas is discharged to atmosphere through an exhaust pipe.

 Clamps and rubber mounts called hangers support the exhaust system under
the vehicle.

Parts of Exhaust System

 Exhaust Pipe: A tubing used to guide waste exhaust gases away from a
controlled combustion inside an engine.

 Silencer: It is installed along the exhaust pipe to absorb noise of the

engine.

 Exhaust Manifold: It collects the exhaust gases from multiple cylinders

into one pipe.

 Catalytic Converter: It is used to minimize the negative effect of two-

wheeler exhausts.

Importance of Exhaust System

 Exhaust system is a very important part of a two-wheeler. Without an

exhaust system, the engine can build up contaminants and sludge, which
can rob the vehicle of horsepower.

 It absorbs the deafening noise produced while the exhaustive gas is being
pushed out of the vehicle's system.

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Silencer

A Silencer is a device for reducing the amount of noise emitted by a

machine such as an internal combustion engine. The noise reduction is due to
destructive interference in the silencer. It is also known as Muffler.

Characteristics of Silencer

 It is installed along the exhaust pipe of the engine.

 Usually, it contains a series of baffles to absorb sound.

 It is usually slung under the rear of the vehicle.

 It forces engines to work harder in the process of pushing exhaust gas

through them.

Types of Silencer

 There are two types of silencers used for two-wheelers

 Two-stroke silencer

 Four-stroke silencer

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 Functions of Silencer

The main purpose of the silencer is to absorb sound released by the

internal combustion of an engine making it comfortable for the rider and others
as well.

Maintenance of Silencer

Silencers should be replaced if they are worn or damaged.

It is important to find out why the silencer is saturated with oil. It can be the
result of a clogged oil return channel or incorrect drum rotation.

Gear Parts

A gear is a toothed wheel designed to transmit the force to another gear or

toothed component. The teeth of a gear is known as cogs. They are shaped to
minimize wear, vibration and noise and at the same time maximize the
efficiency of power transmission. Gears of different size, the larger one is
called a wheel and the smaller one is called a pinion, are used in pairs so that
the force of the driving gear can produce a larger force in the driven gear, that
also at a lower speed or it can be for the purpose of producing a smaller force at
a higher speed.

Parts of a Gear

The parts which make up the gear of a two-wheeler are:

 Gear Box
 Gear Levers
 Gear Cross Rods

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  Gear Oil
Maintenance of Gear Parts

 The lever parts should be lubricated periodically for smooth operation

and protection from wear and tear.

 The gear lever need adjustment from time to time.

Gear Levers

Gear lever is a mechanical device used for engaging and disengaging

gears. Gear lever, along with the clutch lever under the left hand and a twist
grip throttle on the right handle bar controls the transmission.

How a Gear Lever works

A gear lever shifts gears when it it is pressed or lifted. A normal two

wheeler is put in first gear by pressing the gear lever, and it has to be lifted to
put into second or further gears. But for racing motorcycle, pressing the gear
lever always shifts up and lifting it shifts down because all the gears are put
below the first gear.

Normally, two-wheelers have five or six forward gears. Only a very few
specific ones have a reverse gear. Materials used for making Gear Levers
Some of the materials most commonly used for making Gear Levers are:

 Carbonic steel

 Alloy steel

 Aluminum

 Maintenance of Gear Levers

 Gear levers should be lubricated from time to time.They should be

checked for wear and tear from time to time.

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Battery

The first battery was created by Alessandro Volta in 1800. The main
purpose of a standard automotive battery is to provide power to a vehicle's
starter. The three most important things about a automobile battery are its
amp/hour rating, its chemistry and its voltage.

Characteristics of Battery

 Battery has two terminals: One(+), or positive and the other(-), or

negative.
 Battery is the vehicle's initial source of energy used to start the engine.
 A typical two wheeler can be rated at 12 amp/hour.
 On an average, a two wheeler battery last about three years.
 Battery acid is very corrosive and will eat through metal.
Functions of Battery

 It enables the engine to start with the electrical starter.

 It works as an extra power supply when the vehicle needs it.

 It is used for operating the lighting and accessory systems.

 It acts as an electrical shock absorber, protecting vital electrical

components from burning out during high voltage/current output.

 Maintenance of Automotive Battery

 During winter season a charger should be used to keep it topped.

 The battery should be checked to see if they are securely fitted, the cables
are attached securely and the vent hose routed properly.

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 WORKING PRINCIPLES

 The power supply 230 v is supplied to the step down transformer unit.

 Then the input device 12v considered by transformer unit. The

microcontroller unit act as a control unit. It is a storage device. Totally
two programmed are write in the IC. The name is IC is 8095.

 When the break drum comes to the failure condition, the relay indicates
the signal to led set.

 And also the one from of the engine over heat alarm is consists by the
thermistor unit. It indicate the engine over heat condition. When the
Thermistor come to overheat condition, the buzzer is alarmed.

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 COST OF ANALYSIS

SL.NO NAME OF PARTS QUANDITY RATE

1 Microcontroller nit 1 Rs. 1000

2 Thermistor 1 Rs. 150

3 Relay driver 1 Rs.650

4 Break failure system 1 Rs.250

5 Transformer 12v step down 1 Rs.600

6 Mica sheet kit Rs.1000

7 Working cost Rs.2000

Total Rs.5650

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 ADVANTAGES

 Low cost automation project

 Less power consumption

 Operating principle is very easy

 Installation is simplified very much

 Less time and more profit

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DISADVANTAGES

 This circuit is not working on low rain fall

 This system applied in the case of water falling on the class period only

 Addition cost is required to install this system to four-wheeler

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 APPLICATIONS

 Four-wheeler application

 Two-wheeler application

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 CONCLUSION

This project may be developed with the full utilization of men, machines,
and materials and money. Also we have followed thoroughly the study of time
motion and made our Project economical and efficient with the available
resources.

This system was Designed, Fabricated successfully and also tested. It

works satisfactorily. We hope that will be done among the most versatile and
interchangeable one even in future.

Thus we can able to obtain the Automatic break failure indicator and
engine over heating alarm by using electric power.

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 REFERENCES

Electrical and electronics engineering

By Mr. Parasuram

Basic engineering

By Mr. Gupta

Production Technology

By Mr. K.P. Jain

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PHOTOGRAPHY

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