THERMAL BUCKLING BEHAVIOUR OF

AUTOMOTIVE CLUTCH DISC USING FINITE

ELEMENT ANALYSIS
Group Members: Nishar Alam Khan 19MCD0042
Sital Kumar Sah 19MCD0040
Ashoka Nand Jha 19MCD0041

Under the guidance of

Prof. Dr.Mallikarjuna Reddy D
Clutches
 INTRODUCTION

 Clutch is a mechanical device that engages and disengages the power

transmission system.
 The basic application of clutch is to connect and disconnect driving shafts
and driven shafts.
 Automotive clutches can fail at elevated temperatures and thermal stresses
due to the frictional heat generation at the contact surfaces during clutch
engagements.
 Important failure mechanisms include thermal buckling, thermoplastic
instability or hot spotting, thermal cracking, and thermo-elastic
instability.
 Thermal buckling is believed to be one of the dominant failure
mechanisms in clutch plates due to their small thicknesses.
 Buckling is high at inner side than outer side of the disc due non-
uniform temperature variation.
 MATERIALS USED FOR CLUTCH PLATE DISC

Composite Materials:
1. Kevlar
• Kevlar is the synthetic material developed in 1965.
• Chemical name of Kevlar is poly-para-phenylene-terephthalamide.
• A high-durability material more resistant to hard use.
2. Sintered brass
• Sintered brass is used because of their resilience at high loads and high
temperatures.
• As well as their low cost in comparison to alternative friction materials.
• Sintered brass material is much softer as compared to the opposing
hardened steel plates.
3. Silicon carbide
• Silicon and carbon with chemical formula SiC.
• It is used in applications requiring high staying power, such as car brakes,
car clutches, grinding wheels, cutting tools.

 LITERATURE REVIEW

S.N Published TITLE AUTHOR JOURNAL

. Year

1. 2017 Finite Element Analysis on Friction Plate Of G. Shanthi1, International Research

a Wet Multiple Clutch by Using Various S. Praveen Journal of Engineering
Friction Materials Kumar and Technology
(IRJET)
2. 2016 Finite Element Analysis of Thermal Buckling Jiaxin Zhao, Journal of Thermal
in Automotive Clutch Plates Zhuo Chen, Stresses
3. 2015 Experimental Study and Thermal Analysis on Xiong Cenbo Journal of Thermal
the Buckling of Friction Components in , Ma Biao, Li Stresses
Multi-Disc Clutch Heyan

4. 2013 Buckling and Free Vibration Behavior of an P. JEYARAJ International Journal of

Isotropic Plate Under Non uniform thermal Structural Stability and
Load Dynamics
5 2013 Static and Dynamic Buckling of Thin-Walled T. Kubiak Springer International
Plate Structures Publishing Switzerland
 OBJECTIVES

 To design the clutch plate disc and obtain the critical buckling temperature.
 To obtain the various thermal behaviors of the materials used in our project.
 To calculate the critical buckling temperature using mathematical
formulas as well as Ansys software.
 To compare the obtained results from both methods and check
approximation
 Suggest which material will be suitable for clutch plate disc among them.
 METHODOLOGY

.
 MATERIAL PROPERTIES

Properties Aluminum A-360 Alloy Properties of grey cast iron

Young’s modulus of 70×103 N/mm2 Young’s modulus of 165×103 N/mm2

elasticity (E) elasticity (E)
Poisson’s ratio (ν) 0.33 Poisson’s ratio (ν) 0.26
Melting point (M) (557-596)C Melting point (M) 1380C
Coefficient of thermal 13×10-6/C
Coefficient of thermal 21×10-6/C
expansion (α)
expansion (α)
Density (ρ) 2.63×10-6 kg/mm3 Density (ρ) 7.25×10-6 kg/mm3
FINITE ELEMENT MODEL
CONCLUSIONS
Centrifugal clutch
 It is works on the principle of centrifugal force. Centrifugal force
is increases with the increase in speed.
 It consists of spider having radial guide, sliding shoes, helical
tension springs co-axial drum
 The spider having four equally spaced radial guides is keyed to
the driving shaft. Sliding shoes can slide radially in guides.
 The sliding shoes are covered with frictional material from outer
side. These shoes are held against spider on driving shaft by
helical tension springs and all these assembly is enclosed in
coaxial drum which is mounted on driven shaft.
 Coupling

 Shafts are mostly available up to 7 meter length due to

transport difficulty. To get a greater length, it is necessary
to joint two or more pieces of the shaft using coupling.
 Purposes of Coupling used are,
 To connect shafts of motor and generator which are
manufactured separately and to provide for disconnection
for repairs.
 To reduce the transmission of shock loads from one shaft to
another.
 To allow misalignment of the shaft or to introduce
mechanical flexibility.
 To introduce protection against overloads.
 Types of couplings

(1) Rigid coupling

 It is used to connect two shafts which are perfectly in axial
alignment. These couplings do not allow any relative rotation
between the two shafts.
 There are basic three types of rigid coupling as follows,
 Sleeve or muff coupling
 Clamp or split muff or compression coupling
(2) Sleeve or Muff coupling
 Construction
 This is the simplest type of rigid coupling. It is made from cast
iron and very simple to design and manufacture. It consists of a
hollow cylinder (muff) whose inner diameter is the same as
diameter of the shaft.
 The hollow cylinder (muff) is fitted over the ends of the two
shafts with the help of taper sunk key. A key and sleeve (muff)
useful to transmit rower from one shaft to the other shaft. It has
no projecting parts.
3) Split muff coupling (clamp coupling)
Construction
 In this coupling, the muff or sleeve is made into two halves parts
of cast iron and they are join together by bolts as shown in
Figure. Both the halves are held together by means of M.S stud
OR nut/Bolts.
(c) Flange coupling
 There are basic two types,
 (1) Unprotected type flange coupling
 The projected portion of one of the flange and
corresponding recess on other flange are help to bring the
shafts into line and to maintain alignment.
 (2) Protected type flange coupling
 In order to prevent catching clothes of workmen in coupling the
flange is provided with a shroud which shelters the bolt head &
nuts . This coupling is called protected type flange coupling.
(2) Flexible couplings
 This coupling is used to protect the driving and driven machine
members against harmful effects produce due to misalignment of
shafts, vibration, and sudden shock load or shaft expansion.
 There are basic three types of flexible coupling as follows,
 Bushed pin type flange coupling
 Oldham coupling

 Universal coupling
a) Bush pin type flange coupling
 This is a modified form of protected type flange coupling

 This type of coupling has a pins and it work as a coupling bolts.

The rubber or leather bushes are used over the pins. The coupling
is having two halves are dissimilar in construction. The pins are
rigidly fastened by nuts to one of the flange and kept loose in the
other flange.
(b) Oldham’s coupling
 Construction
 It consists of two flanges A and B with slots and a central floating
disc as shown in fig.
 Use
 Connecting two parallel shafts but not in alignment, and their
axes are at small distance apart.
 (c) Universal coupling


 Construction
 It consists of two similar forks keyed on the ends of the two
shafts. These two forks are assembled to a central block by pin. A
central block having two arms at right angle to each other.
 Brakes

 Brake is a device by means of which an artificial frictional

resistance is applied to a moving body in order to retard or stop
the motion of a body.
 During braking process, the brake absorbs either kinetic energy or
potential energy or both by an object.
(a) Single block or shoe brake
 Construction
 It consists of blocks which are pressed against the surface of a
rotating drum by means of lever.

 The friction between friction lining on the block and drum retards
the rotation of the drum. The block or shoe is made up of softer
material than the rim of the drum.
b) Pivoted block brake
 Construction
 A pivoted block brake is shown in figure 11.15. Unlike
single block brake, in this the shoe is pivoted to lever to
get uniform wear.
(c) Double block or shoe brake
 This load produces the bending of the shaft. It can be prevented
by using a double block or shoe brake having two blocks on the
two sides of the drum.
(B) Band brake
 Construction
 It consists of a rope, belt or flexible steel band lined with
frictional material which is wrapped partly round the drum.
 Working
 When band is pressed against the external surface of drum, the
frictional force between drum and band will induce braking
torque on the drum.
 There are two types of band brake,
 (a) Simple band brake
 (b) Differential band brake
(a) Simple band brake
 Construction
 In this brake one end of the band is attached at the fulcrum of the
lever while the other end is at a distance 'b' from fulcrum.
(b) Differential band brake
 Construction
 In a differential band brake, neither end of the band is attached to
the fulcrum of the lever. The two ends of band are attached to the
two points on opposite side of the fulcrum as shown in figure

 The lever AOC is pivoted at fulcrum '0' and two ends of band are
attached at points A and B.
(c) Band and block brake
 Construction
 It consists of number of wooden blocks fixed inside a flexible
steel band.
(C) Internal expanding shoe brake
 It consists of two semicircular shoes S1 and S2 pivoted at the fixed
fulcrum O1 and O2 respectively. The outer surfaces of the shoes
are lined with friction material

 One end of the shoe is pivoted at fulcrum while the other end is
subjected to the actuating force. The actuating force on both the
shoes is applied by hydraulic cylinder or cam mechanism.
Thank you